Decoiler with lockable control post swivel junction

Abstract

A decoiler for spooled strip and wire materials includes a motorized platform for supporting a coiled spool of material on a base. An upstanding control post has a guide which feeds material from the spool to a metal forming machine under predetermined tension. A horizontal support arm mounted on the base has an outer end supporting the control post. A lockable swivel joint pivotally connects the support arm with the base to shift the same between a wide variety of different feed positions, and includes a lock that retains the control post in a selected feed position.

Description

BACKGROUND OF THE INVENTION

The present invention relates to automatic decoilers, dereelers, uncoilers, and other similar devices, and in particular to an automatic decoiler for wire, flat metal stock and the like, having a lockable control post swivel junction that permits shifting the control post between a wide variety of different feed positions.

Many industrial operations require the use of a continuous feed of wire or flat stock to make various types of metal parts. Decoiler machines, which are also known as uncoilers, turntables, unwinders, horizontal payoffs, powered payoffs, etc., have been developed to feed wire and/or flat stock from spools of coiled material to an associated metal forming machine. The fabrication of metal parts is often performed by die stamping or similar metal forming machines, which are positioned at different locations in the fabrication facility. Heretofore, each metal forming machine required its own decoiler to ensure proper material feed. Alternatively, a decoiler would need to be moved from one location to another to ensure correct positioning adjacent a metal forming machine, and would then need to be anchored in place before operation.

It is much more economical to use one decoiling machine that can feed various sizes and shapes of feed stock to the plurality of different metal forming machines positioned in a juxtaposed relationship within a fabrication facility. Thus, there exists the need for an improved decoiler that can facilitate feeding various sizes and shapes of feed stock to more than one metal forming machine, without relocating either the metal forming machines or the decoiler.

SUMMARY OF THE INVENTION

One aspect of the present invention is a decoiler for spooled strip and wire materials having a base shaped for support on a floor surface adjacent at least one associated metal forming machine. A platform is rotatably connected with the base and shaped to support thereon a spool of coiled material disposed in a normally generally horizontal orientation. A motor is mounted on the base, operably connected with the platform, and selectively rotates the platform in a normally generally horizontal plane to pay the coiled material off of the spool. A material control post is disposed in a generally upstanding orientation along side of the platform, and includes a material guide shaped to pass uncoiled material from the spool thereover and apply preselected tension to the material to facilitate smoothly feeding the material to the associated metal forming machine. A control is operably connected with the motor and the material control post to selectively actuate the motor and uncoil the coiled material from the spool in response to tension applied to the material. A control post support arm extends outwardly from the base, and has an inner end thereof and outer end thereof supporting the material control post at a preselected laterally spaced apart distance from the platform. A lockable swivel junction pivotally connects the inner end of the control post support arm with the base to shift the control post support arm and the material control post with the material guide thereon along a generally horizontal plane between a wide variety of different feed positions about the base to facilitate effective presentation of the material to the associated metal forming machine, and includes a releasable lock which securely retains the control post support arm in a selected feed position.

Another aspect of the present invention is to provide a decoiler which can be readily adapted to pay the coiled material to an associated metal forming machine in either a clockwise or counterclockwise direction by simply shifting the control post support arm from one side to the other, which is particularly beneficial when forming heavier materials. Furthermore, the payoff or coil does not need to be moved from side to side, as is required with conventional decoilers.

Another aspect of the present invention is to provide a decoiler that has an uncomplicated design, and can be readily adapted to feed various sizes and shapes of feed stock to a plurality of different metal forming machines. The decoiler is efficient in use, economical to manufacture, capable of a long operating life and particularly well adapted for the proposed use.

These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a decoiler embodying the present invention.

FIG. 2 is a perspective view of a lockable swivel junction portion of the decoiler.

FIG. 3 is a top plan view of the lockable swivel junction.

FIG. 4 is a side elevational view of the lockable swivel junction.

FIG. 5 is a bottom plan view of the lockable swivel junction.

FIG. 6 is a vertical cross-sectional view of the lockable swivel junction taken along the line VI-VI, FIG. 4.

FIG. 7 is a fragmentary perspective view of the decoiler, shown in a first feed position, wherein a platform portion thereof is shown in broken lines to assist in revealing internal construction.

FIG. 8 is a perspective view of the decoiler illustrated in FIG. 7, shown in a second feed position.

FIG. 9 is a partial diagrammatic top plan view of the decoiler, showing the control post support arm in three different positions to feed stock to three separate metal forming machines positioned at different locations.

FIG. 10 is a perspective view of an alternative embodiment of the lockable swivel junction portion of the decoiler.

FIG. 11 is a side elevational view of the alternative lockable swivel junction shown in FIG. 10.

FIG. 12 is a perspective view of a triangular gusset portion of the alternative lockable swivel junction shown in FIG. 10.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper”, “lower”, “right”, “left”, “rear”, “front”, “vertical”, “horizontal” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The reference numeral 1 (FIGS. 1-5) generally designates the decoiler embodying the present invention. The illustrated decoiler 1 is a fully automatic pallet decoiler or dereeler adapted to handle various sizes and shapes of spooled strip and wire materials, such as the illustrated spool or coil 2 of metal strip 3. In the illustrated example, decoiler 1 includes a base 4 shaped for support on a floor surface adjacent at least one associated metal forming machine, such as the metal forming machines 5, 5a and 5b illustrated in FIG. 9. A platform 6 (FIGS. 1-6) is rotatably connected with base 4, and shaped to support thereon the spool or coil 2 of strip material 3 in a normally generally horizontal orientation. It is to be understood that platform 6 is configured to support thereon an entire pallet of pancake or oscillated wound coil, as well as other forms of coiled material. A motor 7 is mounted on base 4, and is operably connected with platform 6 to selectively rotate platform 6 in a normally generally horizontal plane to pay the coiled material 3 off of the spool or coil 2. A material control post 8 is disposed in a generally upstanding orientation along side of platform 6, and includes a material guide 9 shaped to pass uncoiled material 3 from spool 2 thereover and apply preselected tension to the material to facilitate smoothly feeding the same to an associated metal forming machine 5. A control 10 is operably connected with motor 7 and material control post 8 to selectively actuate motor 7 and uncoil the coiled material 3 from spool 2 in response to tension applied to the material. A control post support arm 11 extends generally horizontally from base 4, and has an inner end 12 and an outer end 13 supporting material control post 8 thereon a preselected laterally spaced apart distance from platform 6. A lockable swivel junction 14 pivotally connects the inner end 12 of control post support arm 11 with base 4 to shift control post support arm 11 and the material control post 8 with material guide 9 thereon along a generally horizontal plane between a wide variety of different feed positions about base 4 to facilitate effective presentation of the material 3 to one or more associated metal forming machines 5, 5a, 5b, as shown in FIG. 9. Swivel junction 14 includes a releasable lock 15 which selectively retains control post support arm 11 in a selected feed position.

The illustrated material control post 8, associated guide 9 and control 10 each have a generally conventional construction, wherein guide 9 can be shifted longitudinally along the length of material control post 8 and locked in place in different locations to facilitate smoothly feeding the material 3 to associated metal forming machines. Furthermore, material control post 8 is movably mounted on the outer end 13 of control post support arm 11, and shifts slightly in response to tension on strip 3, which in turn activates control 10, so as to selectively rotate platform 6 to pay the material 3 off of the coil or spool 2.

In the example shown in FIGS. 1-5, a support beam 20 is fixedly mounted on base 4, and extends outwardly from the forward side of base 4 to support swivel junction 14 thereon. The illustrated swivel junction 14 includes a guide plate 21 fixedly supported on the outer end of support beam 20 in a generally horizontal orientation, and includes an arcuate slot 22 that extends vertically through guide plate 21. In the illustrated example, guide plate 21 has a generally square plan configuration defined by opposite sides 23-26, as well as upper and lower, mutually parallel faces 27 and 28. In the example shown in FIGS. 1-6, slot 22 has a continuous, semi-circular plan shape, and guide plate 21 also includes a circular pivot aperture 29, which extends vertically therethrough at a location concentric with the center point of slot 22.

Swivel junction 14 also includes an attachment bracket 32 which is movably supported from guide plate 21 and operably supports the inner end 12 of control post support arm 11. In the illustrated example, attachment bracket 32 includes a hollow sleeve 31 having a substantially rectangular lateral cross-sectional configuration defined by top and bottom surfaces 33 and 34, as well as side surfaces 35 and 36. Two retainer plates 37 are mounted on the bottom surface 34 and side surface 35 of sleeve 31, and include tapped apertures in which fasteners or set bolts 38 are mounted and extend into the interior of sleeve 31 and engage the bottom and adjacent side surface of control post support arm 11 to securely, yet releasably, retain control post support arm 11 in a selected longitudinal position relative to sleeve 31. The top surface 33 of sleeve 31 has two threaded fasteners or studs 40 and 41 fixedly attached thereto, which extend upwardly in a generally vertical direction in a laterally spaced apart relationship. The shank portion of the rearmost stud 40 extends through the aperture 29 in guide plate 21 and thereby permits sleeve 31 and control post support arm 11 to pivot about the vertical axis of stud 40. A washer 42 and nut 43 are assembled on the upper end of stud 40, and serve to assist in locking swivel junction 14 in a set position, yet permit pivotal motion of the same about stud 40. The shank end of the forwardmost stud 41 extends through the arcuate slot 22 in guide plate 21, and has a washer 44 and a nut 45 assembled on the free end thereof, which when tightened, assists in locking the swivel joint 14 in a selected position, yet permits rotation of the swivel joint 180 degrees about the axis of stud 40.

In the illustrated example, control post support arm 11 has a closed channel configuration, having a substantially rectangular transverse cross-sectional shape that is similar to that of the swivel junction sleeve 31. More specifically, the control post support arm 11 is sized to closely fit telescopingly within the interior of swivel junction sleeve 31, as shown in FIGS. 2-6.

In operation, decoiler 1 functions in the following manner to smoothly feed material 3 to one or more associated metal forming machines 5. Initially, the inner end 12 of control post support arm 11 is telescopingly inserted into the interior of swivel junction sleeve 31. The lateral position of the material control post 8 at the outer end of control post support arm 11 can be adjusted by simply shifting the control post support arm 11 inwardly and outwardly through swivel junction sleeve 31. Once the selected longitudinal position for material control post 8 has been achieved, the four lock bolts 38 on swivel junction 14 are tightened to securely retain control post support arm 11 in its preselected lateral position. Next, the nuts 43 and 45 on studs 40 and 41 are loosened slightly to permit the sleeve portion 31 of swivel junction 14, along with the control post support arm 11 mounted therein, to pivot about the axis of stud 40 to the appropriate position to feed material 3 to a selected metal forming machine 5. As best illustrated in FIG. 9, swivel junction 14 permits control post support arm 11 to be shifted 180 degrees in infinitesimally small increments. Once control post support arm 11 is in the selected position, nuts 44 and 45 are tightened so as to securely, but releasably, retain the same therein.

In the example illustrated in FIG. 9, the full lines illustrate the preferred position of control post support arm 11 to feed material 3 from spool 2 to metal forming machine 5. Essentially, swivel junction 14 is shifted so that the control post support arm is disposed in a perpendicular relationship with support beam 20 at the twelve o'clock position, as viewed in FIG. 9. In this position, material 3 is payed off of spool 2 through guide 9 and fed into metal forming machine 5.

Decoiler 1 can be readily adjusted or reconfigured to pay the same or different material to a metal forming machine 5a disposed opposite to metal forming machine 5. Retainer nuts 44 and 45 are simply loosened, and swivel junction 14, along with control post support arm 11, are then rotated 180 degrees to the position shown by the alternating or unequal broken lines in FIG. 9. Retainer nuts 44 and 45 are then retightened to securely, but releasably, retain control post support arm 11 in the new position, wherein the material 3 is fed from spool 2 over guide 9 to metal forming machine 5a.

It is to be understood that swivel junction 14 can also be adjusted or reconfigured to feed material 3 from an associated coil 2 to a metal forming machine 5 disposed anywhere between the previously described metal forming machines 5 and 5a. In the example illustrated in FIG. 9, the equal broken lines illustrate an intermediate position, wherein control post support arm 11 is located in a substantially parallel relationship with support beam 20 to feed material 3 from spool 2 over guide 9 to a metal forming machine 5b.

As will be apparent to those skilled in the art, the adjustability of control post support arm 11 permits the operator to pay the coiled material 2 off of platform 6 to an associated metal forming machine 5 in either a clockwise or counterclockwise direction by simply shifting the control post support arm 180 degrees, which is particularly beneficial when forming heavier metal strips 3. Furthermore, the platform 6 or coil 2 does not need to be moved from side to side, as is required with conventional decoilers.

Hence, it is apparent that swivel junction 14 permits a single decoiler 1, anchored in one position, to be used to supply various forms of wire and strip stock to a plurality of different metal forming machines 5, 5a and 5b, which are positioned in different locations in the manufacturing facility, thereby substantially reducing the costs and time associated with setting up the press operation.

The reference numeral 1c (FIGS. 10-12) generally designates another embodiment of the present invention, having an alternative lockable swivel junction 14c. Since decoiler 1c is similar to the previously described decoiler 1, similar parts appearing in FIGS. 1-9 and FIGS. 10-12, respectively, are represented by the same, corresponding reference numerals, except for the suffix “c” in the numerals of the latter.

In the alternative lockable swivel junction 14 illustrated in FIGS. 10-12, an intermediate reinforcing plate 50 is fixedly mounted to the upper portion of sleeve 31c to provide additional rigidity to the structure. More specifically, reinforcing plate 50 includes a pair of vertical apertures in which the forward and rearward studs 40c are received. In the illustrated example, studs 40c are in the nature of bolts, wherein reinforcing plate 50 abuts against the upper surfaces of the associated bolt heads 51 and is fixedly attached thereto. A pair of triangular gussets 52 are fixedly attached to the lower surface of reinforcing plate 50 and the opposite side surfaces 35 and 36 of sleeve 31 to further rigidify the assembly. A rear support plate 53 is positioned between the top surface 33 of sleeve 31 and the lower surface of reinforcing plate 50 at the rearward side of sleeve 31, and is fixedly attached thereto to provide a very robust, strong assembly. The alternative lockable swivel junction 14c operates in the same manner as lockable swivel junction 14 discussed above.

In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.

Claims

1. A decoiler for spooled strip and wire materials, comprising: a base shaped for support on a floor surface adjacent at least one associated metal forming machine;a platform rotatably connected with said base and shaped to support thereon a spool of coiled material disposed in a normally generally horizontal orientation;a motor mounted on said base, operably connected with said platform and selectively rotating said platform in a normally generally horizontal plane to pay the coiled material off of the spool;a material control post disposed in a generally upstanding orientation along side of said platform, and including a material guide shaped to pass uncoiled material from the spool thereover and apply a preselected tension to the material to facilitate smoothly feeding the material to the associated metal forming machine;a control operably connected with said motor and said material control post to selectively actuate said motor and uncoil the coiled material from the spool in response to tension applied to the material;a control post support arm extending outwardly from said base, and having an inner end thereof and an outer end thereof supporting said material control post thereon a preselected laterally spaced apart distance from said platform;a lockable swivel junction pivotally connecting said inner end of said control post support arm with said base to shift said control post support arm and said material control post with said material guide thereon along a generally horizontal plane between a wide variety of different feed positions about said base to facilitate effective presentation of the material to the associated metal forming machine, and including:a guide portion fixed relative to said base, disposed in a generally horizontal orientation, and including a vertically extending arcuate slot therethrough;an attachment portion operably connected with said control post support arm and having an inner end thereof pivotally connected with said guide portion;a pin supported on an outer end of said attachment portion and closely received in said slot of said guide portion to facilitate rotation of said arm between said feed positions; anda releasable lock which securely retains said control post support arm in a selected feed position.

2. A decoiler as set forth in claim 1, wherein: said guide portion comprises a guide plate fixedly supported on said base;said attachment portion comprises an attachment bracket; andsaid pin comprises a guide pin.

3. A decoiler as set forth in claim 2, wherein: said guide pin includes a threaded shank portion extending through said slot in said guide plate, and a threaded nut portion mounted on said shank portion which abuts said guide plate when said nut portion is tightened to define at least a portion of said releasable lock which securely retains said control post support arm in the selected position.

4. A decoiler as set forth in claim 3, wherein: said attachment bracket comprises a hollow sleeve into which said inner end of said control post support arm is telescopingly received.

5. A decoiler as set forth in claim 4, including: a releasable retainer mounted on said sleeve and selectively engaging said control post support arm to securely retain the same in a selected longitudinal position relative to said sleeve.

6. A decoiler as set forth in claim 5, wherein: said releasable retainer comprises at least one lock bolt.

7. A decoiler as set forth in claim 6, wherein: said arcuate slot has a generally semi-circular top plan shape for pivotally shifting said control post support arm around 180 degrees between selected feed positions.

8. A decoiler as set forth in claim 7, wherein: said arcuate slot is continuous for pivotally shifting said control post support arm in infinitesimally small increments.

9. A decoiler as set forth in claim 8, including: a threaded fastener pivotally connecting said inner end of said attachment bracket with said guide plate and defining at least a portion of said releasable lock for releasably, yet securely, retaining said control post support arm in a selected feed position.

10. A decoiler as set forth in claim 9, wherein: said sleeve has a generally rectangular lateral cross-sectional shape; andsaid control post support arm extends generally horizontally from said base and has a hollow tubular construction with a generally rectangular lateral cross-sectional shape similar to said lateral cross-sectional shape of said sleeve for close telescoping reception therein.

11. A decoiler as set forth in claim 10, including: an intermediate reinforcing plate fixedly connected with an upper surface of said attachment bracket.

12. A decoiler as set forth in claim 2, wherein: said attachment bracket comprises a hollow sleeve into which said inner end of said control post support arm is telescopingly received.

13. A decoiler as set forth in claim 2, wherein: said arcuate slot has a generally semi-circular top plan shape for pivotally shifting said control post support arm around 180 degrees between selected feed positions in infinitesimally small increments.

14. A decoiler for spooled strip and wire materials, comprising: a base shaped for support adjacent at least one associated metal forming machine;a powered platform rotatably connected with said base and shaped to support thereon a spool of coiled material disposed in a normally generally horizontal orientation;a material control post disposed in a generally upstanding orientation along side of said platform, and including a material guide shaped to pass uncoiled material from the spool thereover and apply a preselected tension to the material to facilitate smoothly feeding the material to the associated metal forming machine;a control operably connected with said platform and said material control post to selectively uncoil the coiled material from the spool in response to tension applied to the material;a control post support arm extending outwardly from said base, and supporting said material control post a preselected laterally spaced apart distance from said platform;a lockable swivel junction pivotally connecting said control post support arm with said base to shift said control post support arm and said material control post with said material guide thereon along a generally horizontal plane between a wide variety of different feed positions about said base to facilitate effective presentation of the material to the associated metal forming machine; and whereinsaid swivel junction includes:a guide plate fixedly supported on said base in a generally horizontal orientation, and including a vertically extending arcuate slot therethrough;an attachment bracket operably connected with said control post support arm and having an inner end thereof pivotally connected with said guide plate; anda guide pin supported on an outer end of said attachment bracket and closely received in said slot of said guide plate to facilitate rotation of said arm between said feed positions.

15. (canceled)

16. A decoiler as set forth in claim 14, wherein: said guide pin includes a threaded shank portion extending through said slot in said guide plate, and a threaded nut portion mounted on said shank portion which abuts said guide plate when said nut portion is tightened to define at least a portion of said releasable lock which securely retains said control post support arm in the selected position.

17. A decoiler as set forth in claim 14, wherein: said attachment bracket comprises a hollow sleeve into which an inner end of said control post support arm is telescopingly received.

18. A decoiler as set forth in claim 17, including: a releasable retainer mounted on said sleeve and selectively engaging said control post support arm to securely retain the same in a selected longitudinal position relative to said sleeve.