Patent Application
20220289515
The present disclosure relates to a method of winding a continuous elongate element, such as a wire cable, filament, thread or the like, onto cylindrical elements, such as spools, reels, mandrels or the like. The present disclosure also relates to a system for winding a continuous elongate element, such as a wire cable, filament, thread or the like, onto cylindrical elements, such as spools, reels, mandrels or the like.
Continuous elongate elements, such as wires, cables, filaments threads, etc. are commonly provided in a wound state. For instance, this may be cupper wires for electronic or constructional applications, plastic filaments for 3D printing applications, and of course many other implementations in which it is practical to provide a continuous elongate element in a wound state.
The continuous elongate element can be provided as a coil without any central support, or be supported by a spool or reel, etc. During production, in the case of a coil, the continuous elongate element is initially wound around a mandrel which is subsequently removed. Irrespective of if the continuous elongate element is to be wound around a spool, a reel or a mandrel or any other type of cylindrical element, the production process should suitably be a continuous production process. When the winding of the continuous elongate element onto the cylindrical element has been completed, it should then be winded onto the next cylindrical element, and so on. The switching between cylindrical elements may be time consuming.
In today's production processes for winding a continuous elongate element onto cylindrical elements you normally need to stop some of the equipment at the time of switching to a new and empty cylindrical element. This means that during winding production of the continuous elongate element, which is done at a constant speed, the continuous elongate element needs to be received by an accumulator during switching of cylindrical elements. The higher the production speed and the longer time needed for switching cylindrical elements, the longer portion of the continuous elongate element needs to be accumulated. This leads to the accumulator holding a large portion of the continuous elongate element and the accumulator needs to be very large and requires much space. When the switch is completed, the continuous elongate element needs to be winded onto the new cylindrical element at a much higher speed than the production/feeding speed in order to reduce the length of the continuous elongate element in the accumulator before the next switch occurs. Thus, the rotation of the new cylindrical element needs to be accelerated and be driven at very high speed to make the process work.
It would be desirable to provide an improved method and a system which mitigates at least some of the drawbacks of the prior art.
An object of the present disclosure is to provide a method and a system which mitigates at least some of the drawbacks of the prior art. This and other objects, which will become apparent in the following, are accomplished by a method and a system as defined in the accompanying independent claims.
The present invention is based on the insight that an accumulator may be omitted if a new cylindrical element (which has not yet received the continuous elongate element) is allowed to rotate together with a cylindrical element onto which the continuous elongate element is being winded, and that at the time of switching, the continuous elongate element is engaged so that it does not become unwound from the completed cylindrical element. In particular, the inventors have realized that the two cylindrical elements may be provided on a respective side of a central rotatable member which has an engagement portion which catches the continuous elongate element as it is moved to be wound onto the new cylindrical element.
According to a first aspect of the present inventive concept, there is provided a method of winding a continuous elongate element, such as a wire, cable, filament, thread or the like, onto cylindrical elements, such as spools, reels, mandrels or the like, the method comprising:
Thus, by this method, a continuous winding process is achievable which does not require an accumulator when switching between the first and the second cylinder. The switching is substantially instantaneous.
The central rotatable member may be provided in different conceivable configurations. For instance, it may be in the form of a plate or a disc. It does not necessarily have to be circular or substantially circular. It may, for instance be rectangular or even provided as an X-shape or with a central hub from which a plurality of spokes extend radially. Thus, the rotatable member may have any suitable shape as long as it has an engagement portion with which the continuous elongate element comes into engagement when the feeder is shifted from being aligned with the firs cylindrical element to being aligned with the second cylindrical element.
The above mentioned displacement of the feeder may suitably be performed as a displacement in parallel with the above mentioned geometrical rotational axis. However, other displacement patterns are conceivable as long as the continuous elongate element comes into engagement with engagement portion of the central rotatable member. Furthermore, it should be noted that the feeder may while being aligned with one of the cylindrical elements be displaced back and forth along that cylindrical element so that the continuous elongate element is substantially evenly wound onto that cylindrical element, i.e. the thickness of the winding on the cylindrical element may thus be substantially even along the axial extension of the winding.
The feeder may be any suitable device or arrangement from which the continuous elongate element may be pulled onto the rotating cylindrical elements. It should be understood that the term “feeder” as used in this disclosure should not be construed as limited to a device which actually provides a force to the continuous elongate element for driving the continuous elongate onto the rotating cylindrical elements. Rather the term “feeder” should be understood as a device or arrangement from which the continuous elongate element can be provided to a cylindrical elements be it by a pushing force or pulling force or any other force for making the continuous elongate element to be continuously provided to the cylindrical element. In practice, the rotation of the cylindrical element may provide a pulling force, i.e. pulling the continuous elongate element from the feeder.
The continuous elongate element may be provided to the feeder in various different conceivable ways. For instance, the feeder may be receive the continuous elongate element as it is being produced, such as in a continuous extrusion manufacturing process. Another alternative is that the feeder receives the continuous elongate element from a storage.
The finished product may, for instance, be a spool or reel carrying a wound continuous elongate element portion. However, as mentioned above, the cylindrical element may be mandrel which is removed after the winding, thus leaving a coil of the continuous elongate element.
When the winding of the continuous elongate element onto the first cylindrical element is completed, it may be cut to provide an individual product of the winded continuous elongate element (either supported by the cylindrical element such as a spool, reel etc., or as a coil without an internal supporting core). This is reflected in at least the following exemplary embodiment.
Thus, according to at least one exemplary embodiment, the method comprises, when the continuous elongate element is being wound onto the second cylindrical element,
The cutting may suitably be achieved by means of a cutter having cutting blade, a shearer or any other suitable device or arrangement that can divide the continuous elongate element.
By removing the first cylindrical element, at the time when the second cylindrical element is still rotating, a continuous process is achievable since a third cylindrical element can be arranged at the previous location of the first cylindrical element, ready to receive the continuous elongate element which is currently being wound to the second cylindrical element. This is reflected in the following exemplary embodiment.
According to at least one exemplary embodiment, the method comprises, when the continuous elongate element is being wound onto the second cylindrical element,
This process may thus be repeated back and forth on both sides of the central rotatable member by cutting loose the “completed” cylindrical element (or rather the continuous elongate element portion wound onto that cylindrical element), while the “non-completed” cylindrical element keeps receiving the continuous elongate element as it rotates, and then replace the “completed” cylindrical element with an empty element.
It should be understood that in the case of the method being used for providing a coil, then the same mandrel may be reused. Thus, it may suffice with one mandrel on either side of the central rotatable member, e.g. a first mandrel and a second mandrel. When the continuous elongate element has been wound onto one of the mandrels, say the first mandrel, and the feeder has been displaced such that the continuous elongate element is being wound onto the second mandrel, then after the cutting the of the continuous elongate element, the completed portion of the continuous elongate element may be separated from the first mandrel (thus providing a coil of the continuous elongate element portion) so that the first mandrel becomes ready to receive a new portion of the continuous elongate element when the feeder is eventually returned to become aligned with the first mandrel.
Below will be discussed a system according to a second aspect of the present inventive concept. It should be understood that the features and embodiments presented in the system of the second aspect may also be implemented in the embodiments of the method of the first aspect, and vice versa.
According to a second aspect of the present inventive concept, there is provided a system for winding a continuous elongate element, such as a wire, cable, filament, thread or the like, onto cylindrical elements, such as spools, reels, mandrels or the like, the system comprising:
It should be understood that in some exemplary embodiments the plurality of cylindrical elements may be only two, for example in the case of the cylindrical elements being mandrels used for production of the coils of the continuous elongate element. In other exemplary embodiments, the plurality of cylindrical elements may suitably be a multitude administered from one or more storage and/or supply devices. For instance, empty cylindrical elements such as spools or reels may be stacked and sequentially fed to the central rotatable member when a previous spool/reel has been completed (i.e. winding finished) and removed from the central rotatable member. There may in some embodiments be a single stack for providing empty cylindrical elements to both sides of the central rotatable member, while in other embodiments there may be one stack for each side of the central rotatable member.
The control unit may include a microprocessor, microcontroller, programmable digital signal processor or another programmable device. The control unit may also, or instead, include an application specific integrated circuit, a programmable gate array or programmable array logic, a programmable logic device, or a digital signal processor. Where it includes a programmable device such as the microprocessor, microcontroller or programmable digital signal processor mentioned above, the processor may further include computer executable code that controls operation of the programmable device.
According to at least one exemplary embodiment, the control unit may be configured to receive input parameter values relating to dimensions of an individual cylindrical element of said plurality of cylindrical elements and/or relating to dimensions of the continuous elongate element, wherein the control unit is configured to, based on the received input parameter values, determine when to switch the winding of the continuous elongate element from the first cylindrical element to the second cylindrical element. For instance, an operator may provide information relating to the width of axial length of the windable surface of the cylindrical element. In the case of the cylindrical elements being spools having end walls, the radial extent thereof may be input, etc. Furthermore, it should be understood that the input parameter values do not necessarily need to be input manually, but may be automated, e.g. by the provision of a scanner, RFID, QR-codes, or any other suitable means which allows identification of dimensions or identification of the type of cylindrical element, the dimensions of which may be stored in a look-up table included in or accessible by the control unit.
The radial distance between the engagement portion of the central rotatable member and the common geometrical rotational axis should suitably be larger than the radial distance between the enveloping surface of the completed winding on a cylindrical element and the common geometrical rotational axis. In other words, the thickness of the winding should not be so large that it extends radially as far as the engagement portion of the central rotatable member. Hereby, unwinding of the continuous elongate element may be avoided. In the case of the cylindrical elements being in the form of spools or reels, the radial extension of the end wall portions of such spools or reels is suitably shorter (as seen from the common geometrical rotational axis) than the radial extension of said engagement portion. This is reflected in at least the following exemplary embodiment.
According to at least one exemplary embodiment, each cylindrical element comprises a cylindrical winding portion delimited by a wall portion at each end of the cylindrical winding portion, wherein, when the first cylindrical element, the second cylindrical element and the central rotatable member rotate around the common geometrical rotational axis, the radial distance between the common geometrical rotational axis and the engagement portion is larger than the radial distance between the common geometrical rotational axis and a circumference of said wall portions of the first and second cylindrical elements. Thus, by having a radially larger extension of the central rotatable member, unwinding may be avoided, while the continuous elongate element is started to be wound onto the next cylindrical element.
According to at least one exemplary embodiment, the engagement portion of the central rotatable member comprises a plurality of protrusions, such as tooth-like, hook-like or barb- like protrusions, wherein the plurality of protrusions present abutment surfaces for catching the continuous elongate element as the feeder is moved from being aligned with the first cylindrical element to being aligned with the second cylindrical element.
It should be understood that the engagement portion, for example protrusions thereof, have the function of providing a substantially fixed point for the continuous elongate element. In other words the point of the continuous elongate element that has come into engagement with the central rotatable member will be umovable (at least temporarily, such as until the continuous elongate element is cut) relative to the central rotating member the first cylindrical element and the second cylindrical element. Thus, that unmovable point will rotate with the same rotational speed as the other components. By having a point of the continuous elongate element unmovable relative to the portion (first) cylindrical element with its completed winding, there is no risk of continuous elongate element becoming unwinded. By having a point of the continuous elongate element unmovable relative to the (second) cylindrical element which starts to receive the continuous elongate element, the fixed point ensures that the continuous elongate element “gets a grip” around the cylindrical element during rotation thereof, as the continuous elongate element is continuously pulled from the feeder.
According to at least one exemplary embodiment, the system comprises a cutter, wherein the control unit is configured to control the cutter to cut the continuous elongate element at its engagement with the engagement portion so as to split it into two portions, a first portion already wound on the first cylindrical element and a second portion which is still being winded onto the second cylindrical element.
Suitably, the control unit is programmed such that the cutting is performed a certain period of time after the second cylindrical element has started to receive the continuous elongate element. In particular, the cutting is suitably performed, when the second cylindrical element has made a sufficient number of rotations for the continuous elongate element to become self-locking, i.e. so that the continuous elongate element has been sufficiently winded onto itself, to avoid the risk of unwinding after the cutting is performed.
There are various ways to achieve the cutting action. For instance, according to at least one exemplary embodiment, the central rotatable member comprises a circular slit extending along the periphery of the central rotatable member, wherein the circular slit is configured to receive the cutter for enabling the cutter to split the continuous elongate element into two portions. In other exemplary embodiments, the cutter may instead cut the continuous elongate element on the side of the central rotatable member.
According to at least one exemplary embodiment, the system comprises
By having two separate motors which are individually controllable, the control unit may keep operating one of the motors for winding the continuous elongate element onto the cylindrical element that the motor is operatively connected to, while temporarily deactivating the other motor replacing a full cylindrical element or making the cylindrical element ready to receive a new portion of the continuous elongate element. The control unit may also synchronize the rotational speed of the motors for making a smooth transition when the feeder is displaced from being aligned with one of the cylindrical elements to becoming aligned with the other one.
Although the rotation of the central rotatable member may, in some exemplary embodiments be controlled by the control unit individually, such as by means of a third motor, a convenient solution is to let the rotation of the central rotatable member be controlled by the same motor that is currently rotating the cylindrical element onto which the continuous elongate element is currently being wound onto. This is at least partly reflected in the below exemplary embodiment.
According to at least one exemplary embodiment, the first rotatable shaft is provided with a first spindle which is displaceable along said geometrical rotational axis, the first spindle being provided with a first magnet,
wherein the second rotatable shaft is provided with a second spindle which is displaceable along said geometrical rotational axis, the second spindle is provided with a second magnet, wherein the central rotatable member is provided with one or more magnetic portions, for magnetically connecting the central rotatable member to the first magnet and the second magnet to enable the central rotatable member to rotate with cylindrical elements held by the first and second rotatable shafts.
The first and second spindles (with their respective magnets) may suitably be retractable and advanceable within the respective rotatable shafts. Thus, even though a magnet is retracted, thus disconnecting it form the central rotatable member, the associated rotatable shaft may still hold the cylindrical element at the central rotatable member. Thus, the magnetic connection and the displacement of the cylindrical element may be individually controlled. In other words, the axial displacement of the spindle may be individually controlled relative to the axial displacement of the associated rotatable shaft. The first and second magnets may be of any suitable type, such as permanent magnets or electromagnets.
According to at least one exemplary embodiment, after the cutter has cut the continuous elongate element, the control unit is configured to disconnect the first magnet from said one or more magnetic portions of the central rotatable member and axially remove the first cylindrical element from the central rotatable member which continues to rotate with the second cylindrical element. Although maintaining the central rotatable member in place and in rotation provides an easy and smooth handling and removal of the first cylindrical element, it should be understood that other options are also conceivable. For instance, the central rotatable member could be removed together with the first cylindrical element, while the second cylindrical element continues to rotate for receiving the continuous elongate element. In such an option, the control unit would disconnect the second magnet from said one or more magnetic portions of the central rotatable member, while keeping the first magnet connected to the central rotatable member. When the first cylindrical element is returned (irrespective of which of the above alternatives, i.e. with or without the central rotatable member), or is replaced by a third cylindrical element, the control unit suitably initiates rotation of the this cylindrical element before it is brought into its location for receiving the continuous elongate element. More specifically, the control unit suitably makes sure that it arrives at the same rotational speed as the second cylindrical element which is currently receiving the continuous elongate element. Thus, at the time the three units (first cylindrical element, central rotatable member and the second cylindrical element) are brought together they may suitably already rotate at the same rotational speed.
As mentioned above, the cylindrical elements may be re-used (e.g. when being in the form of mandrels which will not form part of the end product for the wound continuous elongate element) or they may be replaced by new cylindrical elements. Thus, according to at least one exemplary embodiment, the control unit is configured to provide a third cylindrical element to the first rotatable shaft to arrange the third cylindrical element at the previous winding position of the first cylindrical element, so that the second cylindrical element and the third cylindrical element are located on respective sides of the central rotatable member such that the second cylindrical element, the third cylindrical element and the central rotatable member have the same geometrical rotational axis and rotate with the same rotational speed.
According to at least one exemplary embodiment, the control unit is configured to control the first and second motor in master-slave-synchronization mode in which the slave is synchronized with the rotational speed of the master, wherein at any given point in time, the one of the first and second motors that is operating a cylindrical element onto which the continuous elongate element is currently being winded is the master, while the other one of the first and second motors is the slave. This is beneficial as it provides a smooth operation of the system.
According to at least one exemplary embodiment, the system comprises at least one roller, wherein the control unit is configured to apply the at least one roller against the already winded portion of the continuous elongate element before the cutter cuts the continuous elongate element. By having a roller applied against the already winded portion of the continuous elongate element, the risk of it becoming unwinded when the cut has been made and the cylindrical element is still rotating, is reduced. Suitably, the roller is held against the winded portion until the cylindrical element has come to a complete rotational stop or has at least decelerated substantially. Suitably, the roller is held against the winded portion until the cut end of the continuous elongate element has been has been secured somehow, such as by means of a sticker, label, or any other suitable securing means.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to “a/an/the element, apparatus, component, unit, member, means, step, etc.” are to be interpreted openly as referring to at least one instance of the element, apparatus, component, unit, member, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated. Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following description. The skilled person realizes that different features of the present invention may be combined to create embodiments other than those described in the following, without departing from the scope of the present inventive concept.
With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples.
In the drawings:
The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which certain aspects of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments and aspects set forth herein; rather, the embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Accordingly, it is to be understood that the present invention is not limited to the embodiments described herein and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. Like reference numerals refer to like elements throughout the description.
As illustrated in
The winding section 8 is here illustrated as having a central part 14 and two side parts 16, which may be at least partly enclosed in a casing. The central part 14 of the winding section 8 is the location at which the cylindrical elements 2 are positioned when they receive the continuous elongate element 4, i.e. when the continuous elongated element 4 is winded onto a cylindrical element 2. The side parts 16 may include various actuating mechanisms, such as motors, for rotating and/or displacing the cylindrical elements 2. However, motors and other actuating mechanisms may also be located in the central part 14. Motors will be discussed in more detail below in connection with the discussion of other drawing figures.
The post-winding section 10, which in some embodiments may be omitted, may be of any suitable form for receiving the cylindrical elements 2 after they have been provided with the thereon winded continuous elongate element 4 (or for receiving winded coils without the cylindrical elements). The post-winding section 10 is here illustrated as including a receiving rail, however other receiver or means of transport (such as conveyors) are conceivable to include in the post-winding section 10.
As illustrated in
Turning to
In
The feeder 22 is displacable such that it can be aligned with either one of the first cylindrical element 2a and the second cylindrical element 2b. For instance, if the feeder is aligned with the first cylindrical element 2a then the continuous elongate element 4 would be providable from the feeder 22 to the first cylindrical element 2a. In order to operate the rotation of the cylindrical elements 2, 2a, 2b for winding the continuous elongate element 4 onto the cylindrical elements, a motor may suitably be provided on each side of the central rotatable member 24. Thus, a first motor 26a is provided for enabling rotation of the first cylindrical element 2a and a second motor 26b is provided for enabling rotation of the second cylindrical element 2b (see
Turning now to
Each one of said rotatable shafts is provided with a respective spindle. Thus, with reference to
As best seen in
Thus, turning back to
From the above, it can be understood that, in general terms, according to at least one exemplary embodiment, the first spindle and the second spindle are rotatably lockable to the first rotatable shaft and the second rotatable shaft, respectively. According to at least one exemplary embodiment, the first spindle and the second spindle are axially movably in a bore of the first rotatable shaft and the second rotatable shaft, respectively (as for example illustrated in the figures). According to at least one exemplary embodiment, the first spindle and the second spindle extend along the common geometrical axis (as for example seen in the figures).
When a cylindrical element is to be removed from the central rotatable member 24, then suitably the associated magnet 32a or 32b is first disconnected from the mating magnetic portion 36 of the central rotatable member 24. This is illustrated in for example
Thus,
From the above, it can be understood that, in general terms, according to at least some exemplary embodiments, the first rotatable shaft and the second rotatable shaft are movable in the axial direction (in this disclosure axial direction refers to the direction of the common geometrical rotational axis) in order to selectively retract the respective cylindrical element from the central rotatable member or advance the respective cylindrical element towards the central rotatable member.
After the first cylindrical element 2a has been removed from the central rotatable member 24, it may be transferred to the post-winding section 10 (
The control unit 20 is suitably configured to control the first and second motor 26a, 26b in master-slave-synchronization mode in which the slave is synchronized with the rotational speed of the master, wherein at any given point in time, the one of the first and second motors 26, 26b that is operating a cylindrical element onto which the continuous elongate element is currently being winded is the master, while the other one of the first and second motors is the slave.
As mentioned previously with reference to
The control unit is configured to provide the first cylindrical element 2a and the second cylindrical element 2b on respective sides of the central rotatable member 24 along the common geometrical rotational axis. This may, for example, be achieved by means of rotatable shafts and spindles such as the ones previously discussed. The control unit is also configured to rotate the first cylindrical element 2a, the second cylindrical element 2b and the central rotatable member 24 with the same rotational speed. This may, for example, be achieved by means of motors, such as the ones previously discussed.
Accordingly, to achieve the situation illustrated in
After this engagement has occurred, the control unit 20 continues to rotate the second cylindrical element 2b for winding the continuous elongate element 4 from the feeder 22 onto the second cylindrical element 2b. Suitably the first cylindrical element 2a and the central rotatable member 24 continuous to rotate with the second cylindrical element 2b for a sufficient number of rotations until the winding of the continuous elongate element 4 on the second cylindrical element 2b has become self-locking.
As best seen in
When the continuous elongate element 4 has been sufficiently secured (self-locked) to the second cylindrical element 2b, it may be cut by the cutter (shown in
With reference again to
The control unit may thus suitably be configured to control the cutter 38 (
The method of the present inventive concept may suitably be performed by the control unit 20. Thus, the above steps, actions, operations, etc. performed by the control unit 20 may suitably be included in the method of the present invention, including exemplary embodiments thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21162123.0 | Mar 2021 | EP | regional |
