The invention relates to a method for the production of helical or coil screens by winding wires of synthetic material into individual coils which are slid one into the other on a working surface, such that they overlap in the transverse direction and are combined by fixing wires parallel to one another to form porous areal formations, wherein, after the winding, the coils are deposited one next to the other on the working surface and on this working surface are brought into engagement by a joining means and are connected with one another using the fixing wires.
Such coil screens, technically also referred to as spiral screens, have been produced since approximately 1970 and have been applied inter alia as liners or drier screens in paper machines. Further application fields are transport belts and slurry dewatering filters.
EP 0 017 722 A1 and the corresponding U.S. Pat. No. 4,346,138 disclose sieve belts and method for their production, in which a coil is generated through a winding means with a rotating and oscillating cone with connected mandrel. The windings have a spacing in order for them to be combined with other coils. Each of these coils is thermoset and deposited separately in one collection container which rotates synchronously with the winding means such that entanglements cannot occur. The further processing of the coils by sliding them laterally into other coils and the sliding of fixing wires into them takes place on separate machines.
A publication of LEO Feinwerktechnik GmbH & Co. KG, Dietzenbach (DE) by the title “Fügemaschine AS-60” describes drawing 60 separately prefabricated coils from 60 storage and transport containers located on a transport cart and connecting them with one another on this joining machine using 59 fixing wires. One half of the coils had herein been generated with right-hand rotation and the other half with left-hand rotation, which were connected with one another in alternating sequence. The known arrangement includes a bench with a working surface and a stand with 60 monofilament coils with fixing wires and a cutting device.
The principle of a winding device is disclosed in (laid-open) application DE-AS 1 956 321.
DE 35 45 805 A1 discloses two controversial paths for the production of planar formations of coiled synthetic monofilaments. On the one hand, the introduction of DE 35 45 805 A1 describes using a winding machine to produce coils with high pitch, e.g., having large winding spacings, for so-called spiral element assemblies and without intermediate storage to supply these coils subsequently directly to a joining device. However, this document does not discuss the positioning of these coils or any further details. On the other hand, in the continuation of the disclosure there is a discussion that a method with intermediate storage in containers is to be preferred; however, that in the case of large prefabricated winding spacings this method leads to knotting of the coils in the intermediate containers, which cannot be disentangled. The disclosure subsequently recommends intermediate storage in several cylindrical containers, however without large winding spacings, and these are subsequently only generated on the way toward the joining device by heating, elongation and cooling. The joining means, denoted here as a guide, in all implementation examples is stationarily disposed and includes up to eight channels, which approach one another at an acute angle and unite to form a channel of twofold width. Subsequently, from maximally eight coils, belt-like joined structures of limited length and width are produced by insertion of fixing wires. These joined structures can subsequently be combined with one another by utilizing further fixing wires. However, with a stationary joining means it is not possible to produce continuously screen and filter belts which have a virtually indefinite width or length. Such additional joining devices, however, are not disclosed in this document.
The known production methods and devices are complex and expensive. For the working bench alone at least one operator is required. A further shortcoming of the production with separate aggregates is the large fraction of scrap material accumulating at every production station. It is herein mandatory that the coils fabricated on the winding machines are absolutely set throughout, to be stress-free and dimensionally accurate since, for reasons of production techniques, at least a portion of the coils must be stored for several days in the storage containers before the coils arrive at the joining bench for further processing. The consequences are correspondingly high initial investments.
The invention, in contrast, addresses the problem of specifying a method and an arrangement with which, in spite of large dimensions, screen belts of coils and fixing wires can be produced with low personnel, energy and investment costs as well as low scrap accumulation with high precision and reproducibility at low time expenditure.
The posed problem is resolved in the above specified method according to the invention thereby that
a) the coils are generated by the at least one winding means above the working surface and, after thermal forming operation, through a movement of the joining means are deposited next to a guide rail on the working surface,
b) each of the succeeding coils, through a movement of its winding means and the joining means succeeding it, is deposited between the guide rail and the previously deposited coil on the working surface, wherein the at least one previously deposited coil through the movement of the joining means is displaced on the working surface transversely to this [joining means] by a measure of the overlap, and that
c) the particular last deposited coils are connected with one another through at least one inserted fixing wire.
Therewith the posed problem is resolved to its full extent thereby that screen belts with coils and fixing wires can be produced at low personnel, energy and investment costs as well as low time expenditure and scrap with high precision and reproducibility and large dimensions. A continuous series of linked operating steps can be combined in a single machine, which has considerably lesser weight and for which a single operator and considerably lesser footprint is entirely sufficient. Running about, interim transports, intermediate storage and the time- and energy-dependent changes entailed therein of the microgeometry of the coils no longer occur.
Material requirement and recycling of scrap are reduced. The potential scrap is reduced to approximately one third of the material utilized. This means a considerable production cost reduction at identical and even better quality. Individual components such as the known heavy winding machines with a weight of, for example, 500 kg, and a separate footprint of approximately 2 m2 can be reduced to a miniature format above the working surface with a weight of less than 5 kg.
In the course of further embodiments of the method according to the invention it is especially advantageous if, either singly or in combination:
the particular coil is guided through an S-shaped guide channel through the guide means, whose upper end is oriented toward the winding means and whose lower end is oriented in the shape of an arc toward the working surface,
in addition to the fixing wires, filler wires are slid into the already combined coils,
The invention also relates to an arrangement for the production of coil screens with at least one winding device, through which wires or filaments of synthetic material are formable into individual coils, and with a working surface on which the coils can be deposited and with at least one joining device through which the coils can be slid one into the other and be combined through fixing wires parallel to one another to form porous areal formations.
To solve the same problem and with the same advantages, such an arrangement is characterized thereby that
a) the joining device is disposed such that it is displaceable over the working surface,
b) the at least one winding device is disposed above the working surface such that the coils after the winding can be deposited one next to the other on the working surface and, after their transverse displacement through the joining device, can be connected with one another through the fixing wires.
In the course of further embodiments of the arrangement according to the invention it is especially advantageous if, either singly or in combination:
a) above a working surface at least one winding device for the coils is disposed and on the working surface a guide rail for depositing and orienting the coils,
b) the joining device succeeds the winding device such that a further coil can be deposited by the joining device on the working surface between the guide rail and the previously deposited coil, and if
c) with the working surface is associated a slide-in device for inserting a fixing wire into the two particular last deposited coils,
the joining device includes an S-shaped guide channel whose upper end is oriented toward the winding device and whose lower end is oriented in the form of an arc toward the working surface,
above the same working surface are disposed spatially offset several winding devices with joining devices such that they are movable,
the joining device is disposed succeeding the winding device, wherein
a) the joining device is movable along the guide rail,
b) the joining device includes an underside and at least one side face in which is disposed a guide channel for the coil, through which the coil can be guided past the underside, and wherein
c) beneath the underside a guide profile is disposed of such height which corresponds to the height dimension H of the coil, wherein the guide profile is implemented in the form of a wedge such that the particular previously deposited coil(s) is(are) are displaceable so far in the transverse direction away from the guide rail that the newly supplied coil can be brought into overlapping engagement with the previously deposited coil,
for the formation and the draw-off of the coil the axes of winding device and forming body are oriented in the direction toward the joining device at an acute angle between 15 and 60 degrees to the working surface,
the winding device is preceded by a braking device for the supplied wire or filament,
for the acquisition of the path course of the coil between the winding device and the joining device a sensor device is disposed, through which discrepancies from a predetermined path course can be acquired and so transmitted to a driving motor that the movement rate of the winding device and of the joining device above the working surface can be adapted to the joining process,
on the working surface a heating apparatus is disposed, through which the areal formation during its passage can be smoothed and be brought to a predeterminable thickness,
if several winding devices are provided, these are disposed on separate carriages which, independently of one another, are disposed on a guide frame above the working surface and are movable over the working surface through one sensor device each for the path course of the coil, a regulation system and the associated driving motor,
the driving motors for moving the winding device are connected via pinions with a common toothed rack disposed on the guide frame,
associated with the winding devices is a further carriage which is connected via a gearing motor and a pinion with a further toothed rack, which [rack] is also disposed on the guide frame, and that the carriage bears at least one supply drum for the wire to be coiled, and/or, if
the carriage with the at least one supply drum can be regulated such that it tracks at a spacing the at least one associated winding device.
In the following an embodiment example of the subject matter of the invention and its operational function and additional advantages will be explained in further detail in conjunction with
In the drawing depict:
In
The coil 5 passes successively through a precisely temperature-controlled heating chamber 6 in which the coil 5 is transformed into a stress-free state through a hot air stream directed transversely thereto. Through a succeeding cooling channel 7 the geometry of the coil 5 is lastly set (oval, racetrack-shaped and the like). The cooling channel 7 is again succeeded by a sensor device 8 for acquiring and regulating the path course of the coil 5 before it enters into the joining device 9, the cooperation of which with the winding device 4 will be explained in further detail in conjunction with
Through the joining device 9 individual coil segments are so deposited on a working surface 10 shown in
The coil screen 12 subsequently passes with regulated speed through transport cylinders 14, which are succeeded by a heating apparatus 15 with planar contact faces for the coil screen 12 through which the coil screen 12 is brought to uniform thickness and is herein smoothed. The coil screen 12 is lastly wound onto a draw-off cylinder 16.
According to
Utilizing the same reference numbers as before,
As depicted here, the winding devices 4 are disposed such that in the direction of transport of the coil screen 12 they are offset by a measure which corresponds to the spacing of two coils 5 interlaced into one another. Transversely to this transport direction the winding devices 4 are disposed offset by such measure that between two winding devices 4 each the heating chambers 6, the cooling channels 7 and the joining device 9 can be accommodated. Supply rollers 11a and 13a for fixing wires 11 and filler wires 13 and the associated slide-in apparatus 11b and 13b are also disposed sequentially one after the other in the transport direction of the coil screen 12.
The movement directions of the carriages 21a and 21b along the guide frame 18 occur parallel to a guide rail 24 disposed on the working surface 10 and which is critical for the joining process of the individual coils 5, which will still be described in further detail in the following.
Carrying forward the previous reference numbers,
Between the end 26a and the above located entrance of the guide channel 9a for the coil 5 is formed under optimal operating conditions a minimally downwardly curved path course which is critical for the winding spacing of the coil 5 and which is to be kept constant. For this purpose in the free path course of the coil 5 a sensor device 30 is disposed whose measuring signals are supplied to a regulation system 31. This [system] subsequently controls, in turn, a driving motor 32 located on carriage 21b, which [motor] engages with a pinion into a toothed rack 33 on the guide frame 18.
An essential element of the invention is the joining device 9, such as is depicted in
In agreement to a large extent with
The changing movement of such groups of winding device(s) 4 and joining device(s) 9, such as are shown in
Further preferred embodiments of the invention will be specified as follows:
As the raw material for the wires or monofilaments, synthetic materials from the group of polyester, Ryton, PEEK, polyamide, PPS and the like are utilized. The winding device, preferably implemented as a winding head, includes an infeed brake preferably implemented as a hysteresis brake, which is electrically regulatable. It is succeeded by a shaping means for deforming round monofilaments into flat wires. The described air contact heating is preferably provided with an electronic regulation to reach and maintain a material-dependent temperature with a maximal fluctuation amplitude of ∀0.5 EC of the particular required setting temperature.
Cutting apparatus for cutting the separate spirals and the coil screens can also be provided as well as draw-off and wind-up apparatus. The fixing wire slide-in apparatus can be provided with setting and centering apparatus as well as with advancing means for the precise positioning of the fixing wire during the joining process. The same applies to an optionally provided injection arrangement for filler wires. Associated with the preferably heatable working surface as the surface of a work bench can be a smoothing arrangement and/or a setting means for the fixing wires. Especially preferred is a complete control or regulation with a PC and a program for the control or regulation of all interface linkages.
Number | Date | Country | Kind |
---|---|---|---|
10 2007 052 594.1 | Nov 2007 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/EP2008/008901 | 10/22/2008 | WO | 00 | 7/19/2010 |