Automatic winder doffing and re-tubing

Information

  • Patent Grant
  • 6663033
  • Patent Number
    6,663,033
  • Date Filed
    Tuesday, April 23, 2002
    22 years ago
  • Date Issued
    Tuesday, December 16, 2003
    20 years ago
Abstract
A forming tube assembly may include an adapter tube configured to extend over at least a portion of a collet of a winder; and at least one forming tube extending around at least a portion of the adapter tube. A forming package assembly may include an adapter tube; and at least one forming package extending around the adapter tube.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates to the production of glass fibers, and more particularly to removing fiber forming packages from a fiber winder and replacing the packages with forming tubes for production of subsequent forming packages.




2. Technical Considerations




In the manufacture of wound strand packages, and in particular glass fiber strand packages, in which continuous strands of fibers are wound around a forming tube on a rotating collet to form the strand package, the problem occurs of removing the package once it has become full, and replacing the package with another forming tube, preferably while not interfering with the continuous strand forming process. It is known in the production of glass fiber strand packages to utilize turret winders so as to minimize the impact of stopping the winder to remove, or doff, the packages from the collet. Although the use of turret winders maintains a generally continuous glass fiber forming operation, they add to the complexity of removing the packages from the collet and re-tubing the collet for the next forming package. Further complicating this operation, oftentimes the collet is used to form multiple packages that must be removed from the collet and replaced with new forming tubes for the next set of forming packages without interrupting the fiber forming process.




U.S. Pat. No. 4,591,106 discloses a method for automatically doffing a full forming package of a rotating collet. A doffing cup is extended over the rotating forming package and is rotated at a speed slightly greater than the speed of the forming package. A liner within the cup is then inflated to contact and grip the strand surface of the forming package. The cup is then retracted to remove the forming package from the rotating collet.




U.S. Pat. No. 4,052,016 discloses a method and apparatus for removing multiple forming packages from a collet by engaging the rearmost forming package on a rotatable collet and pulling this package along the collet to strip the other forming packages from the collet.




EP 0 427 994 131 discloses an apparatus for loading forming tubes on a winder, wherein the apparatus includes a reservoir for storing forming tubes to be mounted on the collet of the winder.




It would be advantageous to provide a system that reduces the complexity and increases the speed of doffing several strand packages from a winder and re-tubing the collet.




SUMMARY OF THE INVENTION




The present invention provides a forming tube assembly comprising: an adapter tube configured to extend over at least a portion of a collet of a winder; and at least one forming tube extending around at least a portion of the adapter tube. In one nonlimiting embodiment of the invention, the adapter tube of the forming tube assembly is made of polypropylene and includes a slit extending along at least a portion of the length of the adapter tube. In another nonlimiting embodiment of the invention, the forming tube assembly includes at least two forming tubes and a starter band extending around a portion of the adapter tube.




The present invention also provides a forming package assembly comprising: an adapter tube; and at least one forming package extending around the adapter tube. In one nonlimiting embodiment of the invention, the adapter tube of the forming package assembly is made of polypropylene and includes a slit extending along at least a portion of the length of the adapter tube and the forming package comprises a forming tube extending around the adapter tube and at least one continuous fiber strand wound around the forming tube. In another nonlimiting embodiment of the invention, the forming tube assembly includes at least two forming packages and a starter band extending around a portion of the adapter tube.




The present invention further provides a method of forming and doffing a forming package, comprising the steps of: (a) positioning a forming tube assembly on a collet of a winder, the assembly comprising: (i) an adapter tube which extends over at least a portion of the collet; and (ii) at least one forming tube extending around at least a portion of the adapter tube; (b) winding at least one continuous fiber strand around the at least one forming tube to form a forming package; and (c) simultaneously removing the adapter tube and forming package from the collet. In one nonlimiting embodiment of the invention, the forming tube assembly includes a plurality of forming tubes, and the winding step includes the step of winding at least one fiber strand around each forming tube of the plurality of forming tubes to form a plurality of forming packages, and the sliding removing step includes the step of simultaneously removing the adapter tube and the plurality of forming packages from the collet.




The present invention also provides a method of re-tubing a collet of a winder, comprising the steps of: positioning at least one forming tube around at least a portion of an adapter tube to form a preassembled forming tube assembly; and positioning the forming tube assembly over a collet of a winder.




The present invention further provides an apparatus for doffing and retubing a fiber winder, comprising: (a) an assembly support, (b) a support plate vertically movable along the assembly support; (c) a first assembly support extending from the support plate for supporting a forming package assembly comprising an adapter tube and at least one forming package extending around the adapter tube, the first assembly support comprising: (i) at least one gripper movable along the first assembly support between a first position and a second position and capable of engaging the forming tube assembly; and (ii) guides to support and guide the forming package assembly on the first assembly support; (d) a second assembly support extending from the support plate for supporting a forming tube assembly comprising an adapter tube and at least one forming tube extending around the adapter tube, the second assembly support comprising: (i) at least one pusher movable along the second assembly support between a first position and a second position and capable of engaging the forming tube assembly; and (ii) guides to support and guide the forming tube assembly on the second assembly support; and (e) a transport system capable of supporting the assembly support and horizontally moving the assembly support.




The present invention also provides a method of removing at least forming package from the collet of a fiber winder and positioning at least one forming tube on the collet, comprising: (a) providing a doffing and re-tubing device having a first assembly support for supporting a forming package assembly comprising an adapter tube and at least one forming package extending around the adapter tube, and a second assembly support for supporting a forming tube assembly comprising an adapter tube and at least one forming tube extending around the adapter tube; (b) aligning the first assembly support with a collet of a winder having a forming package assembly such that an end of the first support is close an end of the collet; (c) engaging the adapter tube of the forming package assembly with the first assembly support; (d) sliding the forming package assembly off the collet and onto the first assembly support; (e) aligning the second assembly support with the collet of the winder such that an end of the second assembly support is close the end of the collet; and (f) sliding a forming tube assembly positioned on the second assembly support off the second assembly support and onto the collet.











BRIEF DESCRIPTION OF THE DRAWING





FIG. 1

is a schematic of a typical glass fiber forming station.





FIG. 2

is an exploded isometric view of a forming tube assembly incorporating features of the present invention.





FIG. 2A

is an exploded isometric view of another embodiment of a forming tube assembly incorporating features of the present invention.





FIG. 3

is an isometric view of a forming tube assembly on a single collet winder incorporating features of the present invention.





FIG. 4

is an isometric view of a forming package assembly incorporating features of the present invention.





FIG. 5

is an isometric view of an adapter tube on a turret winder


20


incorporating features of the present invention.





FIGS. 6 and 7

are isometric views of a doffing and re-tubing device incorporating features of the present invention, with portions removed for clarity.





FIG. 8

is a view through line


8





8


in

FIG. 6

, with portions removed for clarity.





FIG. 9

is a view of a doffing and re-tubing system incorporating features of the present invention, with portions removed for clarity.





FIG. 10

is a view taken along line


10





10


of

FIG. 7

, with portions removed for clarity.





FIG. 11

is a view similar to

FIG. 6

of an alternate embodiment of the doffing and re-tubing device, with portions removed for clarity.











DETAILED DESCRIPTION OF THE INVENTION




The present invention provides a system for doffing at least one forming package, and preferably several forming packages, from a winder and re-tubing the winder for production of additional forming packages. As used herein, the terms “doff or “doffing” means the removal of one or more forming packages from a fiber winder and the terms “re-tube” or re-tubing” means the positioning of one or more forming tubes on the winder. In addition, as used herein, the term “forming tube” means a cylindrically shaped tube member around which continuous fiber strands are wound on a winder, the term “fiber cake” means the assemblage of the continuous strands wound around the forming tube, and “forming package” means the combination of the forming tube with the fiber cake.




While the disclosure of the present invention will generally be discussed in connection with its use in continuous glass fiber forming operations, it will be recognized by one skilled in the art that the present invention is suitable for use with any continuous fiber forming operation wherein the fibers are wound to form forming packages.




The present invention is particularly well suited for use in glass fiber forming operations. Glass fibers suitable for use in the present invention can be formed from any type of fiberizable glass composition known to those skilled in the art, including, but not limited to, those prepared from fiberizable glass compositions such as “E-glass”, “A-glass”, “C-glass”, “ID-glass”, “R-glass”, “S-glass” and E-glass derivatives. As used herein “E-glass derivatives” means glass compositions that include minor amounts of fluorine and/or boron, and preferably are fluorine-free and/or boron-free. Furthermore, as used herein, “minor” means less than 0.5 weight percent fluorine and less than 5 weight percent boron. Preferred glass fibers are formed from E-glass and E-glass derivatives. Such compositions are well known to those skilled in the art. If additional information is needed, such glass compositions are disclosed in K Loewenstein,


The Manufacturing Technology of Continuous Glass Fibres,


(3d Ed. 1993) at pages 30-44, 47-60, 115-122 and 126-135 and U.S. Pat. No. 4,542,106 (see column 2, line 67 through column 4, line 53) and 5,789,329 (column 2, line 65 through column 4, line 24), which are hereby incorporated by reference.




The glass fibers can have a nominal filament diameter ranging from about 3.0 to about 35.0 micrometers (corresponding to a filament designation of B through U and above). For further information regarding nominal filament diameters and designations of glass fibers, see Loewenstein at page 25, which is hereby incorporated by reference.




As discussed above, the present invention is useful in fiber forming operations other than glass fiber forming operations (i.e. “non-glass fiber” forming operations). Suitable non-glass fibers which can be used in accordance with the present invention are discussed at length in the


Encyclopedia of Polymer Science and Technology,


Vol. 6 (1967) at pages 505-712, and U.S. Pat. No. 5,883,023 (see column 10, line 38 through column 11, line 10), which are hereby incorporated by reference.




Referring to

FIG. 1

, a forming station


10


of a glass fiber forming operation includes a forming apparatus


12


having a strand supply device


14


for supplying at least one strand


16


to a winder


18


. As used herein, the term “strand” means a plurality of continuous fibers


20


. Fibers


20


are supplied from a glass melting furnace or forehearth (not shown) containing a supply of a fiber forming molten glass


22


and having a metal bushing


24


attached to the bottom of the forehearth. During the glass melting phase, the glass is typically heated to a temperature of at least about 2550OF (14000C.). The molten glass


22


is drawn through a plurality of nozzles


26


in the bushing


24


and attenuated to form fibers


20


by winding a strand


16


of fibers


20


on a forming tube


28


mounted on a rotatable collet


30


of winder


18


. More particularly, to start the attenuation process, the strands


16


are typically wrapped around the end cap of the collet


30


. When the winder


18


is up to speed, i.e. it is rotating the collet


30


at the speed required to attenuate the fibers


20


and form the desired fiber configuration, the strands


16


are moved from the end cap to their respective forming tubes


28


. Water sprays


32


can be positioned below the bushing


24


to spray water at the newly formed fibers


20


to cool them after being drawn from the bushing


24


. For clarity in the drawing, the refractory materials, cooling tubes and fins typically surrounding the metal bushing have been omitted. Alternatively, the forming apparatus


12


can be, for example, a forming device for synthetic textile fibers or strands in which fibers are drawn from nozzles, such as, but not limited to, a spinneret, as is known to those skilled in the art. Typical forehearths and glass fiber forming arrangements are shown in Loewenstein at pages 85-107 and pages 115-135, which are hereby incorporated by reference. Typically, immediately after the glass fibers


20


are drawn from the bushing


24


and attenuated and prior to the fibers being wound about collet


30


, they are contacted with an applicator


34


to apply a coating or sizing composition to at least a portion of the surface of the glass fibers


20


to protect the fiber surface from abrasion during processing. Typical sizing compositions for glass fibers are aqueous and can include as components, among other constituents, film-formers, lubricants, coupling agents, and emulsifiers. Non-limiting examples of sizing compositions are disclosed in U.S. Pat. No. 3,997,306 (see column 4, line 60 through column 7, line 57); 4,305,742 (see column 5, line 64 through column 8, line 65) and 4,927,869 (see,column 9, line 20 through column 11, line 19); 5,908,689 (see column 4 line 24 through column 7 line 31 and column 15 line 47 through column 21 line 39) and 5,833,021 (see column 6 line 7 through column 9 line-19), which are hereby incorporated by reference. Additional information and further non-limiting examples of suitable sizing compositions are set forth in Loewenstein at pages 237-291, which is hereby incorporated by reference.




The applicator


34


typically includes a roller


36


having a generally cylindrical surface positioned within an enclosure


38


. The enclosure


38


further includes a sizing reservoir. The roller


36


is positioned within the enclosure


38


such that a portion of the roller surface is submerged within the sizing composition. As the roller


36


is rotated within the enclosure


38


, its surface is coated with a film of the sizing which thereafter coats at least a portion of the surface of the fibers which pass over and contact the roller surface, in a manner well known in the art. For additional information regarding applicators, see Loewenstein at pages 165-172, which is hereby incorporated by reference.




A gathering device


40


mounted at the forming station


10


in any convenient manner is used to gather selected groups of fibers


20


and form one or more strands


16


. The strands


16


typically have about 100 to about 15,000 fibers per strand, and preferably about 200 to about 7,000 fibers, and are drawn through the gathering device


40


at speeds of about 2,500 to about 18,000 feet per minute (about 762 to about 5,486 meters per minute). Although not limiting in the instant invention, the gathering device


40


typically divides the fibers


20


to form up to about 20 strands.




The forming apparatus


12


also includes a spiral


42


for placing the strands


16


in a given pattern on the forming tube


28


positioned upon the reciprocating, rotatable collet


30


of winder


18


to produce a forming package


44


. The strands


16


are directed to one of several forming tubes


28


on the winder


18


so that several forming packages


44


(shown in

FIG. 4

) can be formed on the single collet


30


. Sidewalls


46


are positioned to generally enclose the forming station


10


and isolate the bushing


24


, applicator


34


, gathering device


40


, strands


16


and fibers


20


from similar elements in adjacent forming stations Sidewalls


46


also provide support for other devices, such as, for example, additional water sprays and air cooling ducts, that can be used at the forming station


10


in forming the strands


16


.




The present invention provides an apparatus and method for removing at least one, and preferably multiple forming packages from the collet


30


. In the following discussion, the invention is presented in conjunction with doffingmultiple forming packages from the collet of a winder and re-tubing the collet with multiple forming tubes, but it should be appreciated that the present invention can also be used for doffing and re-tubing a single forming package and single forming tube. More specifically, referring to FIG.


2


and as discussed earlier, winder


18


includes rotatable collet


30


adapted to receive one or more forming tubes


28


for forming glass fiber forming packages. Forming tubes


28


are typically made of plastic or reinforced paper. In the particular embodiment of the invention shown in

FIG. 3

, collet


30


is configured to receive three forming tubes


28


A,


28


B and


28


C. When the winding operation is complete, it is difficult and time consuming to remove each individual forming package and re-tube the collet with additional forming tubes for the next set of forming packages. In addition, the fiber strands that have been wrapped around the collet end cap must be cut and removed from the collet before the strand packages can be removed.




To solve this problem, the present invention uses an adapter tube


50


, as shown in

FIGS. 2

,


3


and


4


, to position forming tubes on and remove forming packages from the collet


30


of winder


18


. More specifically, adapter tube


50


extends generally along the length of the collet


30


and the forming tubes


28


are fitted around the adapter tube


50


to form a forming tube assembly


52


. As used herein, the term “forming tube assembly” means the combination of one or more forming tubes


28


, and optionally a starter band


54


(discussed below), on an adapter tube


50


, as shown in FIG.


2


. Although not required, in one nonlimiting embodiment of the invention, the forming tube assembly


52


can be preassembled and positioned as a single unit on the winder collet


30


to simultaneously re-tube the collet


30


with multiple forming tubes


28


and prepare the collet


30


for subsequent winding of the strands


16


to form forming packages, as will be discussed later in more detail. During the winding operation, strands are wound around the forming tubes


28


to form multiple forming packages


44


and a forming package assembly


56


as shown in FIG.


4


. As used herein, the term “forming package assembly” means the combination of one or more forming packages


44


, and optionally starter band


54


, on an adapter tube


50


. When the winding operation is complete, all the forming packages


44


in the forming package assembly


56


can be simultaneously removed from the collet


30


by sliding the adapter tube


50


from the collet


30


, as will be discussed later in more detail.




The present invention also incorporates the use of a starter band


54


. The starter band


54


is positioned on adapter tube


50


as shown in

FIGS. 2-4

and replaces the need to wind the fiber strands


16


around the collet end cap to begin the fiber attenuation process. More specifically, in the fiber winding operation of the present invention, the fiber strands are wound around the starter band


54


as the collet


30


is rotating to begin the fiber attenuation. When the speed of the collet


30


reaches that required to provide the desired fiber size, the strands


16


are moved from the starter band


54


to their respective forming tubes


28


to form the forming packages


44


. After the forming package assembly


56


is removed from the winder collet


30


, as will be discussed later in more detail, the starter band


54


can be removed from the adapter tube


50


and compressed or deformed so that the fiber strands


16


wound around the band


54


can be removed and the band


54


can be reused.




It should be appreciated that although

FIG. 2

shows the use of the adapter tube


50


in combination with a single collet winder


18


, the present invention can be use on a turret winder of a type well know in the art. More specifically, referring to

FIG. 5

, turret winder


118


includes two collets


130


and


131


secured to a rotatable plate


112


. In the winder arrangement shown in

FIG. 5

, a forming tube assembly


152


including an adapter tube


150


, a starter band


154


and forming tubes


128


positioned thereon, is mounted on upper collet


130


and the glass fibers are wound around forming tubes


128


. A second forming tube assembly


153


including an adapter tube


151


, a starter band


155


and forming tubes


129


, is positioned on lower collet


131


. When the formation of the forming packages on the upper collet


130


is complete, plate


112


rotates in the direction indicated by arrow


114


to move collet


130


from its upper position to the lower position previously occupied by collet


131


, and to move collet


131


from its lower position to the upper position previously occupied by collet


130


. The strand can then be engaged by starter band


155


and subsequently directed to the appropriate forming tubes


129


on adapter tube


151


to form the next set of forming packages while forming package assembly, which includes adapter tube


150


and forming packages incorporating forming tubes


128


, is removed from collet


130


. Once removed, a preassembled forming tube assembly comprising an adapter tube, starter band and forming tubes can be slid over collet


130


as strand is being wound around forming tubes


129


, so that collet


130


can be rotated to its original position after formation of forming packages on forming tubes


129


is complete.




Adapter tube


50


should be sufficiently strong so that the tube will not rip or break when the forming package assembly


56


is removed from the collet


30


during doffing and sufficiently stiff so as not to buckle when the forming tube assembly


52


is slid onto the collet


30


during re-tubing. In addition, it is preferred that the adapter tube


50


be made from a flexible material so that it can conform to the changing shape of the collet


30


, as will be discussed later. Although not limiting in the present invention, adapter tube


50


is made from reinforced paper, rubber or plastic material. Non-limiting examples of suitable plastics include polyester materials, epoxy materials, polyolefin materials, e.g. polypropylene, and combinations thereof.




Although not required, in the nonlimiting embodiment of the invention shown in

FIG. 3

, tube


50


includes a slit


58


along at least a portion of its length so that its diameter can be easily reduced to facilitate removal of the forming packages


44


and positioning of new forming tubes


28


along the adapter tube


50


. In addition, the slit


58


allows the diameter of the adapter tube


50


to increase to conform to the expanded surface configuration of the collet


30


which results when the collet fingers (not shown) extend from the surface of the collet


30


during winding to increase its effective diameter and engage and secure the adapter tube


50


. As the diameter of the collet


30


and adapter tube


50


increases, the adapter tube


50


firmly engages the forming tube


28


and starter band


54


. As shown in

FIG. 2A

, an adapter tube


51


, in another nonlimiting embodiment, can include a slit


58


that extends along the entire length of the adapter tube


51


.




It is preferred that the adapter tube


50


extend slightly beyond starter band


54


and end


60


of the collet


30


so that a doffing and re-tubing device (shown schematically in

FIGS. 6

,


7


and


9


and will be discussed below in more detail) can grip end


62


of the adapter tube


50


and pull it off the collet


30


along with forming packages


44


and starter band


54


, as well as push adapter tube


50


along with multiple forming tubes


28


and a starter band


54


onto the collet


30


to re-tube the winder


18


.




In one nonlimiting embodiment of the invention, adapter tube


50


is made of reinforced paper and includes a slit


58


along its entire length. Although not limiting in the present invention, the adapter tube


50


was combined with reinforced paper forming tubes


28


and a 3-inch wide, reinforced paper starter band


54


positioned about 2.5 inches (6.35 cm) back from the end of the adapter tube


50


.




In another nonlimiting embodiment of the invention, adapter tube


50


is formed from a polypropylene tube having a wall thickness of about 0.066 inch (1.68 mm). The tube included a 0.3125 inch (7.94 mm) wide slit


58


that extends along most of its length, with the slit terminating approximately 1.75 inches (4.45 cm) from the end


62


of the tube


50


, i.e. the end of the tube that is engaged by the doffing and re-tubing device. The polypropylene adapter tube has an 11.83 inch (30.05 cm) inner diameter to fit over a nominal 12 inch (30.48 cm) diameter collet. In one nonlimiting collet configuration the collet has a collapsed diameter of about 11.61 inches (29.49 cm) and an expanded diameter of about 11.91 inches (30.25 cm). Approximately 1.75 inches (4.45 cm) of the end


62


of adapter tube


50


extends beyond end


60


of collet


30


so as to provide a portion of the adapter tube


50


that can be engaged by the doffing and re-tubing device. The starter band


54


used in combination with this embodiment of the adapter


50


is a 2.25 inch (5.72 cm) wide polyurethane band that includes a series of annular ribs on its outer surface that engage the fiber strand as fiber attenuation is initiated. The diameter of the forming tubes


28


is sized to fit over both the collet


30


and polypropylene adapter tube


50


.




In one nonlimiting embodiment of the invention, the collet


30


of winder


18


includes an expandable end cap


64


(shown in

FIG. 3

) and the starter band


54


is positioned approximately 2.5 inches (6.35 cm) back from end


62


of tube


50


so that when the forming tube assembly


52


is positioned on the collet


30


, the starter band


54


is positioned over the end cap


64


of the collet


30


. The end cap


64


is expanded after forming tube assembly


52


is positioned on the collet


30


to ensure tight fit of the starter band


54


as the strand is wound around the starter band


54


during initiation of fiber attenuation. In one nonlimiting endcap configuration, the endcap expands from a diameter of about 11.44 inches (29.06 cm) to about 11.92 inches (30.28). In one nonlimiting embodiment of the invention, the doffing and re-tubing device expands the end cap


64


after positioning the forming tube assembly


52


on collet


30


and retracts the end cap


64


prior to removal of the forming package assembly


56


so that the adapter tube


50


, starter band


54


and forming packages


44


can be removed from the collet


30


. Although not limiting in the present invention, the end cap


64


can be configured as taught in U.S. Pat. No. 5,769,342, which is hereby incorporated by reference. In addition, in a nonlimiting embodiment of the end cap


64


, air pressure is used to inflate and expand the end cap, and the air pressure is released to deflate and retract the end cap.





FIGS. 6

,


7


and


9


illustrate a schematic of the nonlimiting doffing and re-tubing device discussed earlier. In particular,

FIG. 6

illustrates device


200


while supporting a forming tube assembly


52


and a forming package assembly


56


, with portions of the gantry framing removed for clarity.

FIG. 7

illustrates a gantry


202


of device


200


while not supporting any assembly


52


or


56


. Referring to

FIG. 6

, the device


200


includes a gantry


202


supported by an overhead transport system


204


, and in particular a pair of rails


205


. Gantry


202


is supported from and movable via a drive (not shown) along rails


205


by a carriage


206


so that the gantry


202


is horizontally movable from collet to collet along the rails


205


. The gantry


202


is supported from carriage


206


by a support beam


207


which extends from a support post


208


of the gantry


202


. Carriage


206


also includes a set of rails


209


that extends between rails


205


and allows the carriage


206


, and thus gantry


202


, to move in a horizontal direction transverse to the rails


205


, and more specifically, move toward and away from a collet. The carriage


206


can also rotate about a vertical axis to provide rotation of the gantry


202


, as will be discussed later in more detail. The support post


208


of gantry


202


is slidably engaged by a support plate


210


of a support assembly


212


. A drive (not shown) is used to move the support plate


210


and support assembly


212


vertically along the support post


208


, as will be discussed later in more detail. Referring to

FIG. 7

, the gantry


202


further includes a frame


213


positioned opposite support post


208


and supported by support beam


207


and side beams


215


and


217


.




Support assembly


212


of gantry


202


further includes assembly supports


214


and


216


that are secured to and extend from support plate


210


. In the particular embodiment of doffing and re-tubing device


200


shown in

FIGS. 6

,


7


and


9


, the upper assembly support


214


is used to remove a forming package assembly


56


from a winder


18


while the lower assembly support


216


is used to re-tube the winder


18


with a preassembled forming tube assembly


52


. Referring to upper assembly support


214


, a plurality of gripper mechanisms


222


are moveable along the length of the support assembly


214


between a first position, wherein the gripper mechanisms


222


are at end


224


of assembly support


214


and a second position as shown in

FIG. 6

, wherein the gripper mechanism is positioned adjacent to support plate


210


. When at their first position, the gripper mechanisms


222


can engage end


62


of an adapter tube


50


of a forming package assembly


56


positioned on collet


30


of winder


18


. The gripper mechanisms


222


can then move to their second position and pull the forming package assembly


56


off the winder collet


30


and slide it onto the upper assembly support


214


, as shown in FIG.


6


and will be discussed later in more detail. The lower assembly support


216


similarly includes a plurality of gripper mechanisms


226


moveable along the length of the lower assembly support


216


between a first position adjacent the support plate


210


as shown in

FIG. 6

, wherein gripper mechanisms


226


can engage end


62


of an adapter tube


50


of a forming tube assembly


52


supported on assembly support


216


, to a second position at end


228


of the lower assembly support


216


, wherein as the gripper mechanisms


226


move from their first to second position, they push the forming tube assembly


52


off the lower assembly support


216


and onto the collet


30


of a winder


18


. Drive assemblies for the gripper mechanisms


222


and


226


are not shown for clarity; however, as would be appreciated by one skilled in the art, the gripper mechanisms


222


and


226


can be moved along rails or any other type of guide system and can be reciprocated by a variety of different types of drive systems well known in the art, such as but not limited to gears, ball screws and linear actuators.




In one nonlimiting embodiment of the invention illustrated in

FIG. 8

, the upper assembly support


214


include three gripper mechanisms


222


mounted on a support


250


that slides along a rail


252


that extends the length of the support assembly


214


. Without limiting the present invention, in the embodiment shown in

FIG. 8

, each gripper mechanism


222


includes a reciprocating member


254


with teeth extending from its outwardly facing surface


256


. To engage the adapter tube


50


when positioned at the end


62


of the adapter tube


50


, as will be discussed later in more detail, member


254


moves outward and presses a portion of tube end


62


against a backing plate


258


to secure the portion of end


62


therebetween. Gripper mechanism


222


can then move along upper assembly support


214


and slide forming package assembly


56


with forming packages


44


along the upper assembly support


214


. If desired, lower support assembly


216


can include the same type of slide arrangement. However, since the weight of the forming tube assembly


52


is less than that of the forming package assembly


56


, it is expected that fewer gripper mechanisms


226


will be required on lower assembly support


216


. Assembly support


214


can also include guide plates


230


,


232


and


233


, and assembly support


216


can include guide plates


235


and


237


along which the adapter tube


50


of the forming package assembly


56


and forming tube assembly


52


can slide on the respective assemblies as the assemblies are removed from or positioned on the collet


30


of winder


18


.




The following is a description of one nonlimiting method in which the doffing and re-tubing device


200


shown in

FIGS. 6

,


7


and


9


can be used in a glass fiber forming operation. In particular, referring to

FIG. 9

, a system includes a plurality of collet winders


18


and a plurality of package supports


260


with doffing and re-tubing device


200


positioned therebetween. At the beginning of the operating cycle, the upper assembly support


214


of support assembly


212


is empty with gripper mechanisms


222


at their first position, and the lower assembly support


216


includes a forming tube assembly


52


with gripper mechanisms


226


at their first position. The gantry


202


moves horizontally along the support rails


205


until it is aligned with a winder


18


that has completed a fiber winding cycle and its collet


30


is supporting a forming package assembly


56


. In one nonlimiting embodiment of the winder


18


, after the fiber winding cycle is complete, the collet


30


is indexed outward from the winder


18


along the collet centerline. This moves the forming package assembly


56


away from the forming station


10


and makes it more accessible by the doffing and re-tubing device


200


. The support plate


210


and support assembly


212


then moves vertically along the support post


208


until the upper assembly support


214


is vertically aligned with the collet


30


. The carriage


206


then moves horizontally along the rails


209


to move the gantry


202


such that the end


224


of the upper assembly support


214


is positioned inside the over hanging end


62


of adapter tube


50


of forming package assembly


56


and a fitting (not shown) at end


224


can engage the expandable end cap


64


at end


60


of collet


18


, which has been expanded by air pressure to secure the adapter tube


50


and starter band


54


, and deflate it. Gripper mechanisms


222


then engage end


62


of the adapter tube


50


and move to their second position, sliding the forming package assembly


56


off the collet


30


and onto the upper assembly support


214


. Support assembly


212


is then moved to re-tube the collet


30


. More particularly, the support plate


210


moves upwardly along the support post


208


so as to align the lower assembly support


216


with the empty collet


30


and positions end


228


of the lower assembly support


216


adjacent to end


60


of collet


30


of winder


18


. The gripper mechanisms


226


on the lower assembly support


216


then moves from their first position to their second position so as to slide the forming tube assembly


52


off the lower assembly support


216


and onto the collet


30


and a fitting (not shown) at end


228


of lower assembly support


216


engages to the end


60


of the collet


18


and inflates end cap


64


to expand it. The gripper mechanisms


226


then disengage the adapter tube


50


. The gantry


202


is then moved away from the winder


18


by sliding the carriage


206


along rails


209


while the collet


30


is repositioned on the winder


18


to begin the next fiber winding operation. The gantry


202


is then rotated about a vertical axis so that the assembly supports


214


and


216


are now facing the package supports


260


. The gantry


202


next moves horizontally along the rails


205


until the upper assembly support


214


is aligned with an empty package support


260


. The support assembly


212


then moves vertically via support plate


210


along support post


208


to vertically align the upper assembly support


214


with the package support


260


. The gantry


202


is then advanced horizontally along rails


209


to move end


224


of the upper assembly support


214


immediately adjacent end


262


of the package support


260


. The gripper mechanisms


222


then moves from their second position to their first position, thereby sliding the forming package assembly


56


off the upper assembly support


214


and unloading it onto the package support


260


. The gantry


202


is then moved away from the package support


260


along rails


205


and


209


and a preassembled forming tube assembly


52


is positioned on the lower assembly


5


support


216


prior to the initiation of the next cycle. Positioning of the preassembled forming tube assembly


52


on the lower assembly support


216


can be done either manually or automatically.




It should be appreciated that in the above nonlimiting embodiment of the invention, wherein grippers


226


push the forming tube assembly


52


off the lower assembly support


216


, if the grippers


226


are not used to pull any assembly onto the lower assembly support


216


the grippers


226


can be replace with pusher devices (not shown) that simply push the forming tube assembly rather than grip it as does grippers


226


. However, where the lower assembly support


216


must perform additional functions, for example as discussed below, grippers


226


are preferred.




As an alternative to unloading the forming packages, starting tube, and adapter tube of the forming package assembly


56


at the package support


260


, a stripping device


270


as will be discussed later in more detail, can be positioned either on the gantry


202


as shown in

FIG. 7

or at the package support


260


, which will strip the forming packages


44


and starter band


54


off the adapter tube


50


. More particularly, during the unloading operation, after the gripper mechanism


222


has moved from its second position to its first position and unloaded the forming package assembly


56


from the upper assembly support


214


, the stripper device


270


can move into place to engage the adapter tube


50


of the forming package assembly


56


on the package support


260


so that the gripper mechanisms


222


can maintain engagement with the adapter tube


50


and return to their second position on the upper assembly support


214


while the stripper device holds the forming packages


44


and starter band


54


on the package support


260


. In this manner, the adapter tube


50


is slid out from under the forming packages


50


and starter band


54


and is repositioned on the upper assembly support


214


. The adapter tube


50


can then be removed from the upper assembly support


214


either automatically or manually. As an alternative, a new starter band and forming tubes can be positioned on the adapter tube and the doffing and re-tubing cycle can be repeated except that the lower assembly support


216


will now doff the forming package assembly


56


and the upper assembly support


214


will re-tube the collet


30


with a preassembled forming tube assembly


52


.




As another alternative, support plate


210


can be rotated about a horizontal axis so that the upper assembly support


214


moves to the lower assembly support position and the lower assembly support


216


moves to the upper assembly support position. A starter band and forming packages can then be positioned on the adapter tube that is already positioned on the new lower assembly support. It should be appreciated that with these later two alternatives, both the upper and lower assembly supports should have the capability to inflate and deflate the inflatable end cap of the collet.




In one nonlimiting embodiment of the invention and referring to

FIG. 10

, stripper devices


270


is mounted on support beams


215


and


217


of gantry


202


and include a cylinder


274


having a reciprocating piston rod


276


pinned to one end


278


of a pivoting link


280


. The other end


282


of the link


278


includes a stripping member


284


. Link


278


is mounted on support beams


215


and


217


such that it can pivot about mount


286


. In operation, as the forming package assembly


56


is unloaded from the upper support assembly


214


, the stripping device is in a first position as shown in

FIG. 10

to allow the forming package assembly


56


to be removed from the doffing and re-tubing device


200


. More specifically, the rod


276


of cylinder


274


is in a retracted position so that stripping member


284


is spaced from the adapter tube


50


. Once unloaded and while the gripper mechanism


222


is still engaging end


62


of the adapter tube


50


, the stripper device


270


moves to a second position wherein cylinder


274


extends rod


276


, which in turn pivots link


280


about mount


286


and moves stripping member


284


into contact with the adapter tube


50


, as shown in the phantom lines


288


in FIG.


10


. As discussed above, the gripper mechanisms


222


can then move back to their second position on upper support assembly


214


and stripping member


284


will keep the starter band


54


and forming packages


44


on the package support


260


. After the adapter tube


50


is removed from the package support


260


, the stripper device


270


is pivoted back to its first position.




As should be appreciated by one skilled in the art, the movement of the apparatus discussed above and their individual components is controlled by one or more controllers. Although not required, in the particular embodiment of the invention shown in

FIGS. 6

,


7


and


9


, the support post


208


includes a controller


290


to control the doffing and re-tubing operation. It should also be appreciated that several of the movements discussed above can be performed simultaneously. For example, and without limiting the present invention, the support assembly


212


can simultaneously move horizontally along rails


205


and


209


and vertically along support post


208


to align upper assembly support


214


with a collet


30


.





FIG. 11

illustrates a nonlimiting alternate embodiment of a doffing and re-tubing device. More specifically, rather than moving upper and lower assembly supports vertically along a guide post as a forming package assembly is removed from a winder and the collet is re-tubed with a forming tube assembly as discussed above, the doffing and re-tubing device can be configured to position the assembly supports side by side. More particularly, referring to

FIG. 11

, gantry


302


includes a support assembly having a forming package assembly support


314


which extends from a first support plate


310


and a forming tube assembly support


316


which extends from a second support plate (not shown). In operation, gantry


302


moves horizontally along rails


305


and


309


and forming package assembly support


314


moves vertically along support post


308


to align forming package assembly support


314


with a collet of a winder. A forming package assembly


56


is removed from the collet in a manner as discussed above. However, to re-tube the collet, the gantry


302


is moved horizontally and the forming tube assembly support


316


moves vertically along support post


311


to align forming tube assembly support


316


with the collet and the forming tube assembly is positioned on the collet in a manner as discussed above. If desired, forming package assembly support


314


and forming tube assembly support


316


be supported on a common support plate so that both assembly supports move vertically together.




The doffing and re-tubing devices discussed above combine the removal of the forming package assembly and its replacement with a forming tube assembly into a single device. It should be appreciated that the doffing and re-tubing procedures can each be performed by a separate device incorporating the features of the present invention as discussed above.




It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modification which are within the spirit and scope of the invention, as defined by the appended claims.



Claims
  • 1. A method of forming and doffing a forming package, comprising the steps of:(a) positioning a forming tube assembly on a collet of a winder, the assembly comprising: (i) an adapter tube which extends over at least a portion of the collet; (ii) at least one forming tube extending around at least a portion of the adapter tube; and (iii) a starter band extending around at least a portion of the adapter tube; (b) winding at least one continuous fiber strand around the at least one forming tube to form a forming package; and (c) simultaneously removing the adapter tube and forming package from the collet.
  • 2. The method according to claim 1, wherein the removing step comprises the steps of engaging a portion of the adapter tube and sliding the adapter tube with the forming package off the collet.
  • 3. The method according to claim 2, wherein the engaging step comprises the step of engaging an end portion of the adapter tube.
  • 4. The method according to claim 1, wherein the forming tube assembly comprises a plurality of forming tubes, and the winding step comprises the step of winding at least one fiber strand around each forming tube of the plurality of forming tubes to form a plurality of forming packages, and the sliding removing step comprises the step of simultaneously removing the adapter tube and the plurality of forming packages from the collet.
  • 5. A method of re-tubing a collet of a winder, comprising the steps of:positioning at least one forming tube and a starter band around at least a portion of an adapter tube to form a preassembled forming tube assembly; and positioning the forming tube assembly over a collet of a winder.
  • 6. The method as in claim 5, wherein the first positioning step comprises the step of positioning a plurality of forming tubes around at least a portion of the adapter tube.
  • 7. A forming tube assembly comprising:an adapter tube configured to extend over at least a portion of a collet of a winder; at least one forming tube extending around at least a portion of the adapter tube; and a starter band extending around at least a portion of the adapter tube.
  • 8. The assembly according to claim 7, wherein the assembly comprises at least two forming tubes.
  • 9. The assembly according to claim 7, wherein the adapter tube comprises a slit extending along at least a portion of the length of the adapter tube.
  • 10. The assembly according to claim 9, wherein the slit extends along the entire length of the adapter tube.
  • 11. The assembly according to claim 7, wherein the adapter tube comprises at least one of reinforced paper, rubber, and plastic.
  • 12. The assembly according to claim 11, wherein the adapter tube comprises plastic material comprising at least one of polyester materials, epoxy materials, and polyolefin materials.
  • 13. The assembly according to claim 7, wherein the adapter tube comprises polypropylene.
  • 14. The assembly according to claim 7, wherein the at least one forming tube comprises reinforced paper or plastic.
  • 15. The assembly according to claim 7, wherein the adapter tube is cylindrical.
  • 16. The assembly according to claim 7, wherein the starter band comprises a plurality of generally annular ribs.
  • 17. The assembly according to claim 7, wherein the starter band is removable.
  • 18. A forming package assembly comprising:an adapter tube; at least one forming package extending around at least a portion of the adapter tube; and a starter band extending around at least a portion of the adapter tube.
  • 19. The assembly according to claim 18, wherein the forming package comprises a forming tube extending around the adapter tube and at least one continuous fiber strand wound around the forming tube.
  • 20. The assembly according to claim 18, wherein the forming package assembly comprises at least two forming packages.
  • 21. The assembly according to claim 18, wherein the adapter tube comprises a slit extending along at least a portion of the length of the adapter tube.
  • 22. The assembly according to claim 21, wherein the slit extends along the entire length of the adapter tube.
  • 23. The assembly according to claim 18, wherein the adapter tube comprises at least one of reinforced paper, rubber, and plastic.
  • 24. The assembly according to claim 23, wherein the adapter tube comprises plastic material comprising at least one of polyester materials, epoxy materials, and polyolefin materials.
  • 25. The assembly according to claim 18, wherein the adapter tube comprises polypropylene.
  • 26. The assembly according to claim 18, wherein the forming tubes of the forming packages comprise reinforced paper or plastic.
  • 27. The assembly according to claim 18, wherein the adapter tube is cylindrical.
  • 28. The assembly according to claim 18, wherein the starter band comprises a plurality of generally annular ribs.
  • 29. The assembly according to claim 18, wherein the starter band is removable.
  • 30. A forming tube assembly comprising:an adapter tube configured to extend over at least a portion of a collet of a winder; at least one forming tube extending around at least a portion of the adapter tube; and a tube comprising a plurality of annular ribs and extending around at least a portion of the adapter tube.
  • 31. The assembly of claim 30, wherein the tube comprises polyurethane.
  • 32. The assembly of claim 30, wherein the tube is removable.
  • 33. A forming package assembly comprising:an adapter tube; at least one forming package extending around at least a portion of the adapter tube; and a tube comprising a plurality of generally annular ribs and extending around at least a portion of the adapter tube.
  • 34. The assembly of claim 33, wherein the tube comprises polyurethane.
  • 35. The assembly of claim 33, wherein the tube is removable.
  • 36. A method of forming a forming package, comprising the steps of:(a) positioning a forming tube assembly on a collet of a winder, the assembly comprising: (i) an adapter tube which extends over at least a portion of the collet; and (ii) at least one forming tube extending around at least a portion of the adapter tube; (b) initially winding at least one continuous strand on a rotating member carried on the adapter tube, the rotating member being separate from the at least one forming tube; and (c) subsequently winding the at least one continuous fiber strand around the at least one forming tube to form a forming package.
  • 37. The method of claim 36, further comprising transferring the at least one continuous fiber strand from the rotating member to the at least one forming tube.
  • 38. The method of claim 37, further comprising attenuating the at least one continuous fiber strand to a desired prior to transferring the at least one continous fiber strand.
  • 39. The method according to claim 37, wherein the forming tube assembly comprises a plurality of forming tubes, and the subsequent winding step comprises the step of winding at least one fiber strand around each forming tube of the plurality of forming tubes to form a plurality of forming packages.
CROSS REFERENCE TO RELATED PATENT APPLICATION

This is a continuation application of U.S. application Ser. No. 09/572,537, filed May 17, 2000, now U.S. Pat. No. 6,402,078, which is hereby incorporated herein by reference and which claims the benefit of U.S. Provisional Application No. 60/136,537, filed May 28, 1999.

US Referenced Citations (26)
Number Name Date Kind
822224 Ryden May 1906 A
1866622 Corthell Jul 1932 A
3301506 Bagby Jan 1967 A
3388444 Benson Jun 1968 A
3977615 Owens et al. Aug 1976 A
3997306 Hedden Dec 1976 A
4022392 Thomas, Jr. et al. May 1977 A
4023743 Schippers May 1977 A
4052016 Cunningham et al. Oct 1977 A
4340187 Schippers et al. Jul 1982 A
4427158 Conrad Jan 1984 A
4542106 Sproull Sep 1985 A
4591106 Gay May 1986 A
4621778 Paravella et al. Nov 1986 A
4927869 Dana et al. May 1990 A
5207052 Fink et al. May 1993 A
5393003 Watermann Feb 1995 A
5568720 Teich et al. Oct 1996 A
5603460 Reid Feb 1997 A
5769342 Makitka Jun 1998 A
5789329 Eastes et al. Aug 1998 A
5883021 Beer et al. Mar 1999 A
5883023 Martine et al. Mar 1999 A
5908689 Dana et al. Jun 1999 A
6047915 Jaschke Apr 2000 A
6402078 Brockmueller et al. Jun 2002 B1
Foreign Referenced Citations (2)
Number Date Country
0381844 Dec 1989 EP
0427994 May 1991 EP
Non-Patent Literature Citations (3)
Entry
The Manufacturing Technology of Continuous Glass Fibres, by K.L. Loewenstein (3rd Ed 1993) pp. 30-44, 47-60, 85-107, 115-135, 165-172 and 237-291.
Encyclopedia of Polymer Science and Technology, Vo. 6 (1967), pp. 505-712.
PCT/US00/14264 International Search Report, Jan. 2, 2001.
Provisional Applications (1)
Number Date Country
60/136537 May 1999 US
Continuations (1)
Number Date Country
Parent 09/572537 May 2000 US
Child 10/127939 US