The present invention relates to a coiler and a method for manufacturing a coil with at least one winding, wherein a coiler gripper that is arranged on a rotatable coiling disk firmly holds the leading wire-end of a cut length of wire, and fingers that are arranged peripherally on the coiling disk form the cut length of wire into the coil.
The patent application DE 42 35 007 A1 discloses a coiling device for cut lengths of wire wherein the inside walls of a drum serve as resting surfaces for formation of the coil and thereby define the external diameter of the coil. In this device, while the wire is being inserted, the drum remains stationary and is opened when the wire length has been attained and the coil bound. Following transfer of both wire-ends of the coil to transfer grippers, subsequent wire-end processing operations as, for example, crimp pressing and/or seal loading, can be performed. Besides advantages from low moving masses, there are also disadvantages as, for example, uncontrollable bending radii when inserting and compressing the various coil layers for binding. Whether the individual windings always lie against the wall is uncertain. Minimum bending radii on entry and emergence of the wire into, and out of, the drum are also not defined.
From patent specification EP 1 387 449 B1 a coiling device with controllable minimum bending radius for wires, especially optical-fiber wires, has become known. In this device, the cut length of wire is coiled by means of a coiling unit into a coil, and after attaining the correct wire-length the wire-ends are of identical length and after the coil has been bound, the wire-ends are accepted by transfer grippers for further processing. For optical-fiber wires the high outlay for mechanics and controls is more readily justified than for wires with copper conductors.
Patent application WO 03/018456 A1 discloses a coiling device for a coil with a rotating coiling arbor, on which hanging and open able coiling arms are arranged. Depending on the cut length of wire, the arms are opened more or less, so that when the wire length is attained, the two wire-ends are approximately the same length. For processing of the wire-ends, after the coil has been bound it is accepted by transfer grippers.
On many types of wire processing machines, the handling of long cut lengths of wire (for example, greater than 7 meters wire length) is difficult. On swiveling machines with swivel arms, the wire tray must be as long as the cut length of wire. On transfer machines with a transfer unit that can be moved along straight lines, during transportation several loop-shaped wires lie on top of each other, which on rapid transportation by means of the transfer unit can cause relatively high wire-pulling forces because the wire is only held at its ends.
In the said patent applications, solution concepts for transfer machines are shown. Separate coiling devices downstream of the wire processing machine have not established themselves because, with the serial processing operations, the cycle time or total processing time for a coiled cut length of wire was correspondingly long.
It is here that the present invention sets out to provide a remedy. The present invention solves the problem of creating a device and a method for manufacturing long cut lengths of wire without lengthening the total processing time.
The device according to the present invention is particularly suitable for wire processing machines with swivel arms. The device according to the present invention can, however, also be used on transfer machines with linearly movable transportation units if additional grippers and receiving devices for handling the wire-ends of the wire coil are provided.
In the following exemplary embodiment of a wire processing machine with swivel arm, the coiler is arranged between a cutting-off/insulation-stripping unit and a second swivel arm. Coiling of the cut length of wire takes place by means of a coiling disk which, by means of a controlled motor, depending on an also motor-controlled belt drive, is rotatable, the belt drive serving to advance the wire and measure the length of the advanced wire. This arrangement is particularly advantageous for elastic wires. The leading wire-end of the wire that is to be coiled is processed by means of processing stations and, after processing, swiveled back to the cutting-off/insulation-stripping unit by means of a first swivel arm and advanced with the belt drive a short distance, so that the coiler can grip the leading wire-end. The belt drive then advances the wire by the desired length of the cut length of wire, and the coiler coils the advanced wire simultaneously into a coil. After the coiling operation, a linearly movable stacker unit grips the coil. When doing so, the coiling disk pneumatically de-tensions its tension finger and travels pneumatically backwards. Profiled plates acting as remover prevent the coil from being pulled backwards. The stacker unit then moves back with the coil so that the trailing wire-end can be cut off and stripped of insulation and if necessary processed, a second swivel arm feeding the trailing wire-end to processing stations. Grippers of the stacker unit hold the coil, and the deposit unit moves until it is approximately under the swivel point of the second swivel arm and the trailing wire-end can, if necessary, for processing of its end still be pulled out of the coil by means of the second swivel arm. After the trailing wire-end has been processed, the stacker unit moves further in the wire-advancing direction to the deposit. While the trailing wire-end is being processed, and during the travel to the deposit, the coil can be provided with a bind. The coil can be provided with the bind during processing of the trailing wire-end, or during processing of the leading wire-end of the next cut length of wire. Thereafter, the bound coil can be placed into containers, onto transportation belts, or onto other receptors as, for example, arbors.
The advantages achieved by means of the present invention are mainly to be seen in that the binding operation on the coil proceeds simultaneously with the processing operation on the cut length of wire. The total processing time for the cut length of wire, also known as the machine cycle time, is thus not lengthened. The total processing tire remains the same with or without bind. The time for manufacturing the coil is comparable with the time for placing into the deposit a straightened cut length of wire on a conventional wire processing machine.
Mechanically, the coiler and stacker unit are not arranged as a separate device from the wire processing machine, but form an integral unit of the wire processing machine. The cut length of wire that is to be manufactured and processed is cut off to length from the wire stock, its leading wire-end processed, coiled, possibly its trailing wire-end processed, and as a coil with bind handed over to the deposit without any manual intervention being necessary.
Also advantageous is that the wire processing machine, despite long cut lengths of wire, is shorter dimensioned than a conventional wire processing machine. The length of the wire processing machine is not determined by the length of the cut length of wire.
In the wire processing machine according to the present invention, and in the method according to the present invention for manufacturing and processing a cut length of wire, the cut length of wire is cut off to length from a stock of wire and its wire-ends processed, a coiler being provided that forms the cut length of wire into a coil with at least one winding, and a stacker unit with a binding device providing the coil with a bind.
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.
Provided at the entry to the wire processing machine 10 is a wire advancing device comprising a belt drive 11 and a length-measuring device 12. The belt drive 11 feeds a wire 13 to a first swivel arm 14 with a first gripper 15. The belt drive 11 advances the wire 13 and the length-measuring device 12 measures the advanced wire length, the advanced wire length corresponding to the cut length of wire that is to be manufactured and whose ends are to be processed. Not illustrated is the wire stock, for example a wire drum or a wire reel.
By means of drives, the first swivel arm 14 can be set into a swiveling movement symbolized with an arrow P1 and/or into a linear movement that is symbolized with an arrow P2. By means of turning movement P1 and linear movement P2, the first swivel-arm 14 as feeding device serves leading wire-ends 5 to processing stations 16 (for example crimp presses and/or seal-loaders) arranged to the side of the longitudinal axis of the wire KL.
After the leading wire-end 5 has been processed, by means of grippers 15 the first swivel arm 14 brings the leading wire-end 5 back into the longitudinal axis of the wire KL. The wire 13 is than advanced by means of the belt drive 11 until a coiler 17 can grip the leading wire-end 5. The belt drive 11 then advances the defined cut length of wire 1 that is measured by means of the length measuring device 12, and the coiler 17 that is synchronized with the belt drive 11 simultaneously coils the advanced cut-off length of wire into a coil 2 according to
The trailing wire-end 7 of the coiled cut length of wire 1 is grasped by a second swivel arm 19 and set in a swiveling motion symbolized with an arrow P3 and/or in a linear motion symbolized with an arrow P4, the trailing wire-end 7 being fed to processing stations 21 (for example, crimp presses and/or seal loaders) that are arranged at the side of the longitudinal axis of the wire KL.
Before the trailing wire-end 7 is processed, the coil 2 is accepted by coil grippers 22 of a stacker unit 23. The stacker unit 23 then moves in the wire-advancing direction towards a deposit 24 until the stacker unit 23 reaches a position approximately below the swivel arm drive 25 of the second swivel arm 19.
Before processing of the trailing wire-end 7 takes place, a tape station 26 makes a cut length of tape ready for manufacturing the bind 4. The cut length of tape is accepted by a binding device 27 of the stacker unit 23.
After processing of the trailing wire-end 7 has taken place, by means of grippers 20 the second swivel arm 19 brings the trailing wire-end 7 back into approximately the longitudinal axis of the wire KL, and the stacker unit 23 is moved with the coil 2 further in the direction of the deposit 24. During the travel of the stacker unit 23 to the deposit 24, the bind 4 is manufactured by means of the binding device 27. The coil 2 with bind 4 is sorted according to good/bad criteria into one or other of the containers 31 of the deposit 24. A belt drive 28 moves the stacker device 23 by means of the belt 85 along a linear guide 29 that is arranged on a machine rack 30. Entered in
Instead of the adhesive tape 61, a tape with comparable properties can be used. Also suitable, for example, is a plastic tape that has on one side hemispherical heads on short stems arranged in wavelike pattern which, when pressed together, allow formation of a permanent or releasable fastening.
In accordance with the provisions of the patent statutes the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
Number | Date | Country | Kind |
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07107578 | May 2007 | EP | regional |
Number | Name | Date | Kind |
---|---|---|---|
353047 | Young | Nov 1886 | A |
2624771 | Hanson | Jan 1953 | A |
4390137 | Hammond, Jr. et al. | Jun 1983 | A |
5427327 | Anderson et al. | Jun 1995 | A |
5570853 | Teng | Nov 1996 | A |
6948675 | Frommenwiler | Sep 2005 | B2 |
Number | Date | Country |
---|---|---|
30 47 887 | Jul 1982 | DE |
42 35 007 | Apr 1994 | DE |
1 387 449 | Feb 2004 | EP |
1 452 474 | Sep 2004 | EP |
57-131678 | Aug 1982 | JP |
58-112912 | Jul 1983 | JP |
03018456 | Mar 2003 | WO |
Number | Date | Country | |
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20090039194 A1 | Feb 2009 | US |