Patent Application
20150274480
1. Field
The described technology generally relates to a winding spool for a transportable package of an elongated winding material.
2. Description of the Related Technology
EP 0 334 211 B relates to a method for producing a non-packed, transportable package, in which a demountable steel spool is used, onto which a sleeve is placed, the sleeve being made of chipboard or corrugated cardboard. Both the steel spool and the cardboard sleeve have a conically shaped winding core. The winding of the spool starts at the end of the winding core having the smaller diameter, and it is carried out by a laying means, which is moving parallel to the longitudinal axis of the spool, so that the length of the winding layers, viewed in the longitudinal direction of the spool, is substantially continuously increased, thus resulting in a so-called biconical structure of the winding.
The drawing of the cable from this package is usually carried out from the still standing spool and with a vertically oriented longitudinal axis, wherein here the winding core having the smaller diameter is arranged at the bottom. During the drawing of the cable over the upper spool flange, the part of the package remaining on the spool remains stable due to the biconical structure, so that the entire cable can be withdrawn without interference. This winding method is now used by many cable manufacturers.
Another method for the producing of a transportable package is described in EP 0 504 503 B 1. For this transport system, a conical winding core consisting of plastic is used, wherein a flange is arranged at its end having a larger diameter. At the end having the smaller diameter no flange is provided.
For the winding, the winding core having the large flange diameter is arranged downwards in a winding device, and a disk, which is made of metal and which is a part of the winding machine, is connected as a substitute for an upper spool flange with the winding core. After the winding, the metal disk in the machine is removed again and the package is provided with a foil envelope for the transport.
The system is very stable for the transport, but it has the disadvantage that, on the one hand, the winding core must be returned to the cable producers for the system to be economical, and on the other hand, the foil envelope must be disposed of by the cable operators.
As a further development of the first mentioned method for the producing of a transportable package, a method is known from EP 0 672 016 B2, in which a specially designed winding spool made of plastic is used. The winding spool, which is shown in
The winding device for the winding of the winding spool is illustrated in
In this context, it should be noted that these spools are used, for example, to supply cables that are used for the producing of wiring harnesses for motor vehicles use. During the producing of the wire harnesses, the required cable piece is drawn at a high speed from the still standing spool, and after the cutting, the cable is held in a holding device until the next piece of cable is needed.
This intermittent drawing with a high drawing speed presupposes a particularly stable winding structure, since a jamming of the cable during the unwinding usually leads to a rupture of the cable and thus to an interruption of the production. For a return transport of the plastic spool, the flange is removed at the end having the smaller diameter and the winding cores and the flanges are stacked to save space. Thus, only a low transport volume is required for the return transport.
The method described last—is usually referred to as the NPS (N(iehoff)-P(aket)-S(ystem); Niehoff package system)—is used by many cable producers throughout the world, particularly for the cable delivery for the automotive industry. However, this delivery system is unable to fulfill all the requirements of the cable users. So the concentration process in the cable manufacturing industry has led to the fact that such packages are transported over long distances and also by ship. Since, in this case, the time of circulation of a spool is so high, that is the amount of time that elapses until the spool coming from the cable producer has been received by the cable user and it has been processed there and transported back, that an extremely high number of the winding spools would be needed.
Since the costs of the spools usually have to be borne by the cable producer, these costs make the use of the system uneconomical in such a case for the cable producer. With an increasing distance, the costs of the returning of the empty spools also increases despite the low transport volume so that the costs of the transport of the empty spools in relation to the value of the spools are too high.
Finally, there are also cable users who shy away from the effort to collect and to return back the empty spools, so that the relatively expensive winding spools of the aforementioned system will be lost for the cable producers. Therefore, the cable producers have the desire for a transport system that works, on the one hand, as reliable as the NPS system, but which, on the other hand, is economically even for the large transport distances.
WO 2005/070802 A1 discloses a winding spool for accommodating an elongated winding material and a method for its production and for the unwinding of the winding material. For this winding spool, there is a part made of a plastic having a low stability, wherein this part can be recycled. Further, a hollow conical section of this spool is constructed as a thin-walled section, particularly the section for accommodating the winding material is constructed as a flexible plastic skin.
One inventive aspect relates to a winding material containing metal, such as wires, strands, cables sheathed with insulation, and the like.
Another aspect is a method of producing a transportable package and a method of unwinding a transportable package of an elongated winding material using a winding spool and a package for a transportable winding material.
Embodiments can be suitable for all elongated winding material, which is usually wound on (winding) spools.
Another aspect is a winding spool for a transportable package and to provide a method of producing the same and to provide a method of unwinding the transportable package and to provide the transportable package, by which an economical and reliable transport system can be realized.
Another aspect is a winding spool for a transportable package for an elongated winding material and for a method of producing the same and for a method of unwinding a transportable package for an elongated winding material using an appropriate winding spool and for a transportable package for an elongated winding material.
Another aspect is a winding spool according to some embodiments, for a transportable package for an elongated winding material that comprises a substantially rotationally symmetrical, conical hollow winding core top made of plastic. Here, the aspect ratio of the wall of this conical section is selected in dependence of the characteristic material values of this plastic, for example, it is selected such that a deformation, especially a deformation affecting the winding in these areas is prevented or reduced.
In some embodiments, a winding core top can be a sleeve-like body, which serves as a top on a carrier system, for example, on a carrier body. As carrier systems or carrier bodies can serve known (carrier) winding spools (carrier spools) or other carrier bodies which are functionally equivalent. The winding core top may not be a winding core of a conventional winding spool.
The conventional winding spools are in direct contact with a winding core top receiving unit of a winding device and have a higher stability and for example, a higher stiffness, than the winding core top according to some embodiments.
However, the winding core top cap according to some embodiments can be supported by such a conventional winding spool or another functionally equivalent carrier system at its winding with a winding material without being in direct contact with a winding spool receiving unit.
The winding core top according to some embodiments has a first end having a smaller diameter and a second end having a larger diameter than that of first end.
A cavity of the hollow winding core top is constructed conical and open at both ends, for example, for accommodating a carrier system and a carrier body, such as a winding core.
Furthermore, the winding core top—as the conventional winding core of a divisible winding spool—is arranged detachably with at least one first flange, which is detachably arranged at the first end of the winding core top, and with at least one second flange, which is arranged at the second end of the winding core top.
The conical hollow section of the winding core top, which is arranged between the two flanges, has a thin-walled construction on a length I (extension between the two flanges) and an average wall thickness t. Furthermore, in some embodiments, the hollow conical section comprises as an essential component, or consists of this, a plastic having a modulus of elasticity (E modulus) in the range of 1000 N/mm2 to 30 000 N/mm2. In some embodiments, an essential component includes a matrix material of a fiber composite material, even when the fiber content is large, and the proportion of the matrix material is low.
The geometric construction of this conical hollow section according to some embodiments is oriented on the characteristic material values of this plastic, at least on its Young's modulus. In some embodiments, the orientation of the construction is such that that a correlation of the geometry factors of the respective section and characteristic material values (Young's modulus) gives this section in the form that for the construction of the winding spool a material with another E modulus, for an otherwise constant geometry, leads to another aspect ratio (l/t) of the hollow conical section.
Here, the aspect ratio according to some embodiments is selected such that the product of the Young's modulus (N/mm2) and this aspect ratio (mm/mm) is greater than 0.1×106, or greater than 0.2×106, or greater than 0.3×106, and less than 2.5×106, or less than 1.5×106 or less than 0.8×106. This product can be substantially 0.5×106.
In some embodiments, for the producing of a transportable package for an elongated winding material, the above winding spool is used.
The winding spool according to some embodiments comprises a rotationally symmetrical essentially conical hollow winding core top made of plastic, having an aspect ratio l/t, which is oriented on the characteristic material values of this plastic, for example, on its modulus of elasticity. This section has a first end having a smaller diameter and a second end having a larger diameter than that of the first end.
A cavity of the hollow winding core top is constructed conical and open at both ends, for example, for accommodating a carrier system and a carrier body, such as a winding core of a so called winding spool, which is shortly called as a carrier spool.
The winding core top is further connected with at least a first flange, which is detachably arranged at the first end of the winding core top, and with at least one second flange, which is arranged at the second end of the winding core top.
For the method according to some embodiments, the winding spool is composed by connecting the first flange detachably with the winding core top on the first end.
The thus composed winding spool is arranged on the carrier system, for example a conventional separable appropriate winding spool, as known from the winding device in EP 0 672 016 B2 (see
The carrier system or the carrier spool together with the winding spool, which is mounted on it, is inserted into a winding apparatus suitable for the winding of the carrier system, for example a known separable winding spool, for example the winding device known from EP 0 672 016 B2 (see
Typically, the insertion of a conventional separable winding spool into a winding device is effected in such a way that the winding spool is accommodated in the winding device by means of two spool holding devices, which center the flanges arranged on both sides of the winding spool and are supported on their surface facing away from the winding core of the winding spool.
The carrier spool can be accommodated into a winding device with the difference that in this case the carrier spool carries the winding spool (as the top to be wound).
In some embodiments, a winding material is wound on the winding spool—and not as for the conventional method on a winding spool directly mounted on the winding device—by using a laying unit, which, for example, as known from EP 0 672 016 B1, is controlled by a control device in such a way that there is a predetermined winding pattern on the winding spool. Once a desired degree of filling of the winding spool has been obtained, the winding operation is terminated and the carrier system or the carrier spool is removed from the winding device together with the winding spool, which has been mounted on it and which has been wound.
The separable carrier spool is separated and the winding spool mounted on the separable carrier spool is detached from the carrier system or the carrier spool. Thus, the transportable package spool is provided by the winding spool, which has been wound up.
Another aspect is a method for the unwinding of a transportable package for an elongated winding material that uses: a rotationally symmetrical essentially conical hollow winding core top made of plastic, which has a first end having a smaller diameter and a second end having a larger diameter than the first end, wherein a cavity of the winding core top is conical and open at both ends, with a first flange and a second flange, wherein the winding core top is connected to at least the first flange, which is detachably arranged at the first end of the winding core top, and to the second flange, which is arranged at the second end of the winding core top, wherein the method has the following method steps: an inserting of the winding spool, which has been wound up, into a winding device, an unwinding of the winding material from the winding spool, which has been wound up, by using an unwinding unit, a terminating of the unwinding operation, as soon as the desired grade of unwinding has been reached, and a removing of the winding spool, which has been unwound up the desired grade of unwinding, from the winding device.
The package has a substantially rotationally symmetrical conical hollow winding core top made of plastic, which has a first end having a smaller diameter and a second end having a larger diameter than the first end. A cavity of the winding core top is conical and open at both ends. The conical hollow section has a particular aspect ratio, wherein this aspect ratio is based on the characteristic material values of the plastic, for example, on its modulus of elasticity.
The package further comprises a flange which is fixedly connected with the second end of the winding core top. Further, the package comprises a cable which is wound on the winding core top according to a predetermined winding pattern.
At least one embodiment is based on the consideration to provide a conventional winding system with a reusable winding spool, such as known from EP 0672016 B1, as a carrier or other functionally equivalent carrier body as a carrier system for a disposable spool, which is to be wound and which can be produced at a lower cost and which has to be provided with sufficient rigidity. Accordingly, at least some embodiments can be clearly described as “a disposable spool which can be mounted on a reusable carrier spool or a functionally equivalent carrier”.
It has been shown in the use of disposable spools, whose section between the two flanges has as an essential component a plastic material or it is consisting of a plastic material, that during the handling of these spools, e.g., during the winding, the unwinding, the storage or the transportation, it may come to irregularities. This means, for example, that the position of the elongated winding material on the winding spool can be changed, so that in the worst case a complete unwinding of the winding material from the spool is no longer possible. For such spools, the flanges are, for example, exposed to high winding pressures and the hollow conical section between the flanges is exposed to lower loads. To be able to accommodate a large winding volume on the winding spool, the hollow conical section is constructed having a small wall thickness, so as a kind of a plastic skin. On the other hand, the flanges are constructed such that they withstand the high winding pressures.
Even when applying the greatest care during the winding of the package, it cannot be ruled out that during the storage and during the transport as well as during the unwinding of the package, that during these operations forces are acting on the winding material, for example, in a radially inward direction. If these forces exceed a certain threshold, then a thin plastic skin in the area of the conical hollow section can no longer resist to these forces. Although the stability of the package would be sufficient for a transport alone, it can then lead to an elastic deformation. As a result, it may therefore be a change in the positions of the winding material, these changes, in turn, can lead to problems during the unwinding of the winding material, or it can lead to the problem that the package can no longer be fully mounted on the winding core top, because the hollow conical section is deformed radially inward.
Further, there are a variety of different sizes of packages, so that a certain wall thickness for a given length of the hollow conical section is sufficient in the sense that the aforementioned problems do not occur, wherein problems occur for the same wall thickness and different lengths of this section. Further, different materials are used in the production of the winding spools having different sizes but in some cases also for winding spools of the same geometry. This results into the problem that the above described problems do not occur at a specific aspect ratio with a specific material, wherein the above-described problems occur for the use of another material and the same geometry.
To enable a safe reliable unwinding of the package, it is therefore necessary to consider both of the geometry and the material as well as the construction in addition to the strength and the stability of the winding spool. Due to the construction of the winding spool, it is possible to construct for the different package sizes and the different materials the winding spool such that on the one hand a safe unwinding is enabled, and that on the other hand the volume of the winding material, which can be accommodated by the winding spool is as large as possible under these conditions.
Further, the advantage of this disposable spools remains preserved in that the carrier system, for example a conventional winding spool, can be used as usual for the direct winding without any conversions necessary on the support system. However, in addition it can be also used for the indirect winding of the original winding spool mounted on the carrier system or the carrier spool, i.e., in this case, the winding spool mounted on the carrier spool. For the unwinding of the winding spool, a carrier system or a carrier body, such as a carrier spool, is not necessary or not indispensable as for the winding.
By the recurring to the conventional winding system made possible by some embodiments, for example, by the recurring to the well-known NPS-winding system, also its advantageous characteristics can be used. So for the winding spool, which has been wound, the same winding pattern can be realized as for the NPS winding spool. Also, partially filled or partially unwound spools can be realized.
On the unwinding, opened packages can be stored again. It can be used the same delivery logistics as well as the same lifting tools as for the NPS winding system and the NPS transport system, respectively. In this way, with the original winding system, known as the NPS winding system, it can be realized advantageously two different winding systems, the reusable NPS winding system and the disposable system with the disposable spool, which can be mounted on it.
The disposable spool, which can be mounted and which has to be wound, comprises similar to a conventional separable reusable spool, such as that of the known NPS winding system, a part, which can be wound and which is similar to a winding core, namely the winding core top which can be mounted on the carrier spool or the winding core of the carrier spool.
Further, similar to a separable winding spool, the mountable winding spool comprises at least one flange, which is detachably connected to the winding core top. A second flange may be fixedly or detachably connected to the winding core top. This separable construction of the winding apparatus allows that a plurality of first flanges and/or a plurality of winding core tops and/or a plurality of winding spools are stackable in an unwound state and/or in a wound state and/or in a transportable state. Therefore, the advantages of the package, such as known from EP 0 334 211 B, can be combined with the advantages of the package, such as known from EP 0 672 016 B1.
Accordingly, the disadvantages of both systems can be avoided by the system of the disposable spool, which can be mounted on a support system and a reusable spool, respectively. Also, at least one of the disclosed embodiments has the advantage that no strapping is necessary for the winding spools, which have been filled.
As materials for the winding spool can be used, for example, plastics, such as polyurethane, polyethylene (PE), polypropylene (PP), polystyrene, acrylonitrile butadiene styrene (ABS). If higher requirements on the stability or higher requirements on the rigidity have to be met, the plastic may be reinforced by appropriate means, for example, with glass fibers. In some embodiments, different components of the winding spool comprise different materials, or are made of different materials, respectively. The conical hollow section of the winding spool can be formed of a material different from the material of the detachable flange. In some embodiments, the detachable flange has as an essential component PE, or consists of this. Further, the conical hollow section as well as the flange integrally formed with it can have as an essential component PP, or consist of this. The reverse combination of the materials described above can also be possible. By the use of the different materials with the different technical characteristics, it is possible to adapt the areas of the winding spool to the stresses occurring there, without requiring a significantly change of the production tools.
In some embodiments, the winding core top is formed of a thin plastic, for example an elastic recyclable plastic such as PP or PE. However, in the area of the hollow conical section of the winding spool, this thin plastic may not be constructed as a plastic skin, but with a significant average wall thickness t, so that a deformation of this section radially inward can be reduced or can be avoided for the forces occurring during the handling of the winding spool. Thus, this winding spool can be quasi rigid. By this rigidity, which can be obtained by the inventive aspect ratio l/t in combination with the modulus of elasticity of the plastic, a safe operation is provided, especially a problem-free unwinding up to the last layer of the winding material, and thus an improved winding spool is provided.
Although for the construction of the winding spool it may not be achieved that winding core top has the minimal wall thickness, which is achievable (a plastic skin) by the manufacturing technology, and thus allowing for the maximum of the elongated winding material to be accommodated on the spool, since the wall thickness in the region of the hollow conical section is not constructed as a plastic skin, but has to suffice to the predetermined aspect ratio.
However, this theoretical loss of the winding volume per winding spool by the construction is (over) compensated in that it is ensured by this construction that the winding material can be unwound completely for each of the winding spools, and that especially in the last layers of the winding material problems during the unwinding of the spool can be reduced or can be avoided, wherein the problems might be caused by an inward deformation of the winding spool, for example, in the radial direction. Despite reducing the theoretical winding volume, thus by reducing the irregularities during the unwinding of the spool, for example, by an avoiding of deformations of the hollow conical section of the spool by the construction of this section, the total of the usable winding volume can be increased, so that an improved winding spool can be provided by the construction.
Due to the low weight and the relatively simple construction, the winding core top can be manufactured in a very cost effective manner, so that the costs of the lost disposable winding spools, e.g., the winding spools according to some embodiments, which are used once, are not significantly relevant the cable producers.
On the other hand, the winding device can be also used in reusable system due to its ability for stacking, which is obtained by the detachable or the separable construction of the winding spool, respectively, wherein for this case, the detachable flange is separated from the winding core top. Thus, the winding spool can be transported in the unwound state by a separating of the winding core top and of the detachable flange and by a stacking of the winding core tops and of the spool flanges to save space. Here, for the spools according to some embodiments having thin-walled winding core tops, up to 250 empty spools can be stacked on a Euro pallet and transported.
If the winding core top, in accordance with some embodiments, is made of a single grade plastic, it can be crushed into pellets immediately after the unwinding of the cable by a grinding unit, which is included in the process line, and the granulate can be further processed at plastic factories in the country of the recipient.
Since the winding core top according to some embodiments is made of plastic, no changes of the geometry or of other characteristics of the packages arise, when the system is transported in hot and/or humid countries.
On the other side, for the countries with hot and/or humid climates, it has been shown that the gray cardboard and/or the corrugated cardboard as a package carrier cause problems as the gray cardboard absorbs water and then warps or depending on the ambient air humidity swells or shrinks, and with any further water absorption it also may disintegrate. It should be noted that during a water transport for several days or weeks the packages are exposed to a very humid climate. Further, on a surface of the winding core top, which is wound with the winding material, a pattern, such as a herringbone pattern or a scale pattern, can be incorporated. As a result, among other things, the static friction can be increased between the winding material and the winding core top, and thus the package can be stabilized.
In some embodiments, at the first end of the conical shaped winding core top, the minor diameter has a diameter of slightly more than 203 mm, being the diameter of a NPS spool, which can be used as a carrier system. This allows the unwinding behavior of the winding spool to be improved. The use of a separable plastic spool as the carrier spool for the winding spool has the advantage that the total weight inserted into the winding device, i.e., the carrier spool with the mounted winding spool remains relatively low. Thus, even at a high rotational speed of the carrier spool, the unbalances, which result from the unavoidable deviations in the diameter, are relatively low.
This means a significant difference from the use of steel spools, as it is conventionally known, since their high weight proves to be disadvantageous, for example, at the high speeds. Also, the two flanges can be made of the above mentioned plastics, for example, they can be made of an elastic recyclable plastic such as PP or PE. Furthermore, the second flange can serve as the unwinding ring. Also, the flanges may be constructed conical and/or cone-shaped, whereby it is achieved that flange a small indention occurs for a constant winding width and thereby a flange pressure in the winding spool is reduced.
In some embodiments, the flanges can be provided with lifting eyes, for example, for lifting tools, and/or with tear tabs, for example, adapted to open a circumferential latching.
In some embodiments, the first detachable flange with a special locking system is connected to the winding core top. Such a locking system can be achieved by using segment latchings, stack borings and/or circumferential latchings, which are at least partially, but preferably in their entirety incorporated in the first flange. In this case, the winding core top has corresponding counterparts, e.g., borings. In this case, these segment latchings, these stack borings and/or these circumferential latchings can be engaged with these counterparts, e.g., with these borings.
In some embodiments, the segment latching or the circumferential latching is constructed such that in an engaged state a substantially continuous profile occurs in the area of the latching. According to some embodiments, latching sections are provided in the hollow conical section, which are constructed as recesses, e.g., as pocket-like recesses. These recesses are adapted to receive in the engaged state the latching projections or the latching intrusions, respectively, which are e.g., arranged in this detachable flange, so that a continuous surface profile occurs. Thus, for example, the inner surface of the hollow conical section and the front surface of this section have a substantially continuous profile, for example, they are not disturbed by stages, steps or the like.
These recesses extend from the front surface of the hollow conical section in the direction to the non-detachable flange (axial direction). These recesses can be constructed such that they have a reduction in the wall thickness in the radial direction in respect to the hollow conical section, e.g., a reduction by a dimension k2.
This dimension k2 is based on the wall thickness of the section of the latching intrusion, which engages into this recess in the engaged state and it is based on the wall thickness t of the hollow conical section outside of this recess. In some embodiments, the latching intrusion comprises, at least partially or completely and the latching section of the hollow conical section have each approximately half the wall thickness t, wherein the latching section is formed as pocket-like recesses. Further, the sum of the wall thickness of the latching intrusion and of the wall thickness of the pocket-like recess can be approximately the wall thickness of the hollow conical section, or equivalent to it.
In some embodiments, these recesses are offset in the axial direction from the front surface of the hollow conical section, e.g., by a dimension k1. These recesses can be offset in the axial direction as such as the thickness of the wall of the latching intrusion in this area. By this offsetting, a shape like a castle battlement is formed, for example, in the hollow conical section in the area of its front side.
By this geometrical adaptation of this pocket-like recesses and of the latching inclusions, for example, a good locking of the detachable flange with the remainder of the winding spool is achieved. A further advantage is that the spool may be particularly well mounted on a carrier spool, for example, so that there a little or no cavity occurs between the hollow conical section and the carrier spool, as it might occur when the surface profile is not continuous in this area.
By this construction of the latching, a shape of the winding spool results being close to an advantageous integral construction of the detachable flange with the remainder of the winding spool.
The circumferential latching may have further gaps, e.g., small gaps, which facilitate the removing of the first flange of the winding core top, for example by tearing of the circumferential latching. Further, a locking system can be realized, which in its operation is similar to the locking systems known for paint buckets.
Furthermore, on one of the flanges, for example, on the first detachable flange, it may be provided a lifting eye for using with a lifting means and/or a handle having a tearing tab for a separating of the at least one flange from the winding core top (cone part). Further, stack borings and/or segment latchings and/or circumferential latchings may be provided in the flanges. Furthermore, ribs can be incorporated into the flanges.
In some embodiments, the connection between the winding core top and the detachable flange is constructed in a form fitting manner, e.g., by means of the latching elements, which are arranged on the winding core top and on the spool flange and which are brought into engagement during the assembly.
In some embodiments, the second flange on the end having the larger diameter of the winding core top is not detachable. The second flange is then preferably formed integrally with the winding core top and can be manufactured together with the latter, for example, by an injection molding process.
In order to facilitate the stacking of the full spools, on the outer sides of the two flanges, i.e., on the side facing away from the winding core top, are provided e.g., projections and intrusions, which engage with each other when the spools, which have been wound, are stacked. By this, the transport of the spools, which have been wound, is further simplified. Borings for the stacking (stacking borings) can be incorporated in one of the two flanges, e.g., in the first detachable flange in order to facilitate the stacking, or to facilitate the centered stacking.
In some embodiments, the winding spool is mounted in such a way on the carrier spool and this carrier spool is inserted in such a way into the winding device that the winding spool is arranged in a vertical arrangement of the spool axis with the smaller diameter of the winding core top facing down in the winding device, and according to known winding methods it is provided with a biconical constructed winding.
The winding spool, for example, the hollow conical section of it is constructed such that a deformation of this section in the radially inward direction is reduced or avoided. According to some embodiments, this is achieved by an aspect ratio, which is oriented on the characteristic material values of the material used in this area, for example, on its modulus of elasticity. For this, it is not sufficient that only the quite high winding pressure at this type of winding can be reliably absorbed by the flanges, but it is also necessary that force effects which may occur in the handling of the winding spool, for example, in the radially inward direction, does not lead to a deformation, for example, of the layers of the elongate winding material. This can be achieved by the construction of the winding spool according to some embodiments.
In some embodiments, a weight is fitted into the cavity of the hollow winding core top, for example, in an area at and/or near the first end of the winding core top. Thereby, the stability of the winding spool can be stabilized, for example, during the unwinding.
For the unwinding of the transportable package, for example, for a cable user, the winding material, in the exemplary case a cable, can be unwounded from the still standing winding spoil, wherein the winding material or the cable, respectively can be unwound up to the last layer without that the stability of the package decreases and leads to problems during removal. The unwinding of the package can be carried out using a NPS unwinding device.
In some embodiments, the transportable package is a cable package, and it is used for the production of wire harnesses for motor vehicles.
If the disposable winding spool is used in a reusable system, the first flange can be removed at the end having the smaller diameter for a return transport of the plastic spools and the winding core tops and the flanges are stacked to save space. Thus, only a low transport volume is required for the return transport. For example, for the transport of the winding spools, a plurality of first flanges and/or a plurality of winding core tops and/or a plurality of winding spools can be stacked in an unwound state and/or in a wound state and/or in a transportable state. Alternatively, for a support spool, such as the known NPS spool, it can be used another functionally equivalent carrier system.
Such an alternative carrier system or such an alternative carrier body, respectively can consist of an elongated body having a plurality of cylindrical or conical sections which support and carry the winding core top in its interior at several positions, especially in areas at the first end and at the second end of the winding core top.
Some embodiments have a number of other advantages. For example, the winding spool or the winding core top is constructed such that it can be accommodated during the winding by a conventional divisible winding spool, as described in European patent EP 0 672 016.
Since such winding spools for the cable producers are available in large numbers, they need not to spend additional costs for the processing of the winding spools. For example, the cable producers can wind the winding spool with the same equipment, by which the spools for the conventional NPS system are wound.
Subsequently, the calculation of the average wall thickness t of the hollow conical section is explained using an example relationship between characteristic material values and the geometry:
The example relationship:
Constraints: the winding spool made of PP, the length of the tapered hollow section is 350 mm:
In some embodiments, the average wall thickness of this section will be approximately 1 mm.
It is noted that the spool can be used in connection with the method according to some embodiments, but that the spools can also be used with other winding methods and with other winding devices. Additional advantages, features and possible uses are shown by the following description of exemplary embodiments in conjunction with the accompanying drawings.
Embodiments will be described below with reference to a typical use case, namely the production of transportable packages for insulated cable, as needed, for example in large amounts for the automotive industry or for the electronics industry. The described embodiments are in no way intended to limit the areas of application or the scope of the present invention.
Embodiments: disposable NPS spools (with a reusable NPS winding system as a carrier system or an alternative carrier system), the embodiments of the disposable NPS winding spool, briefly called disposable NPS spool, are described below in reference to
The reference signs of
The first or the first two digits of a reference sign, respectively identify the respective figure in itself.
In the immediately following, the carrier system is described in detail at first. The reusable NPS winding device, which is generally designated with 100, comprises a first spool accommodating unit 103 and a second spool accommodating unit 104. The (reusable) winding spool 50, which is used as a carrier for the disposable NPS spools according the embodiment, has a conical winding core 52 and a first flange 53 and a second flange 54.
The first flange 53 is arranged at the end of the winding core having a smaller diameter, and the second flange 54 is arranged at the end of the winding core having a larger diameter. The (carrier) winding spool is substantially rotationally symmetrical with respect to the axis 56 extending in its longitudinal direction. As shown, the winding device can be constructed such that the longitudinal axis 56 of the spool is perpendicular, that the first flange 53 is arranged at the bottom and that the second flange 54 is arranged at the top.
The spool accommodating unit 103 is also constructed rotationally symmetrical and it can be rotated around an axis 106. The spool accommodating unit comprises a circular base disk 108, onto which is arranged a supporting disk 109 having a smaller diameter. On the supporting disk 109 is arranged a cone 111, which engages into a correspondingly shaped boring 72 of the flange 53 of the winding spool 50. The winding spool is centered in respect to the spool accommodating unit 103 by this cone. Concentrically to the spool accommodating unit 103, a pulley 115 is arranged, which is driven via a driving belt 117 of a (not further explained) driving means 116.
The upper spool accommodating unit 104 comprises a disk 120, which is attached to a plunger 122. The disk is rotatably mounted around a rotation axis 123, which coincides with the axis 56 of the winding spool and the axis 106 of the lower spool accommodating unit. The punch, as indicated by the arrow 125, is raised and lowered, for which are used piston cylinder units 127 and 128, which are not specified more in detail. The pistons 129, 130 of the piston cylinder units are connected via a yoke 131 with the plunger 127.
A ring 112, which is pointing into the direction of winding spool, is integrally formed on the disk 120, wherein the outer wall of the ring 12 is inclined to the disk 120 and wherein the angle corresponds to the angle of conicity of the winding spool 50. A second ring 131 is integrally formed on the outer periphery of the disk 120 and it also points downwardly onto the winding spool.
The winding device further comprises a laying unit 140, which is provided with a laying roller 142, on which the wire or the cable D is guided to the winding spool. The laying roller 142 is raised and lowered, as indicated by the double arrow 143, in a direction parallel to the axis 56 of the winding spool. For this purpose, the laying unit has a threaded spindle 144, which is extending parallel to a longitudinal axis of the winding spool, wherein the threaded spindle is rotatable in both directions via a driving unit 145. Depending on the direction of rotation of the laying unit, the laying roller will be lifted, that means it moves in direction to the driving unit 145, or it will be lowered again, respectively.
The function of the winding device is controlled by a (not shown) controlling unit. The controlling unit receives signals from sensors indicating the angular velocity of the spool, and signals indicating the relative position of the laying roller 142.
Based on these signals, the driving unit 116 and the driving unit 145 are controlled in such a way that it leads to the desired winding pattern during the winding process on the spool 50—or in the cases of the uses as a support system according to the embodiment on the disposable NPS spool.
Subsequently, the function of this device will be described for the disposable NPS spools according to the embodiment, which applies in the same way to the apparatus, which is used as a carrier system.
By a lifting movement of the piston cylinder units 127 and 128, the plunger 122 is raised, and thus the spool accommodating unit 104 is raised. A winding spool is placed manually, or by an automatically operating unit onto the spool accommodating unit 103, wherein the cone 111 of the spool accommodating unit engages in the boring of the spool accommodating unit, and is centering it.
Subsequently, the punch 122 is lowered with the spool accommodating unit 104 until it abuts on the upper end of the spool. Here, the conical ring 112 is centering the upper end of the winding core having the larger diameter, wherein the ring 131 of the spool accommodating unit supports the flange 54 of the spool.
The end of the wire is then fixed to the lower flange 53, for example by an automatically operating unit, and the laying roller is set into rotation for winding up the wire or the cable, respectively. The controlling of the driving unit 116 and of the driving unit 145 can be done in such a way that results into a winding pattern, as shown in the EP 0 334 211 B, confer for example,
During the winding operation, the lower flange 53 is supported by the supporting disk 109 and the upper flange 54 is supported by the disk 120 of the spool accommodating unit 104 and by the ring 131, respectively. Thus, the flanges cannot be deformed by the winding pressure and by the self-weight of the winding material. Not only the axial forces but also the radial forces, which are acting in the winding spool, are absorbed due to this construction. In the area of the lower spool accommodating unit 103, this is done by the cone 111, which supports the lower flange 53 over a large area. Since the flange, as explained later in the description, can be provided with corresponding reinforcing ribs, this support is sufficient to avoid an undue distortion of the flange despite its low self-weight.
The upper end of the winding core and the flange 54 are supported by the ring 112 and by the ring 113 in a gripper like manner, wherein this ring is supported by a corresponding projection of the flange 54. Thereby, both the radially inward acting forces and the radially outward acting forces are directly absorbed by the disk 120. Therefore, a deformation of the winding core and a deformation of the flange are reliably prevented in this area.
When the spool is completely wound up, the wire can be caught and cut, e.g., by an automatic capturing and cutting unit, and the spool sided end can be also automatically fixed at the spool. Subsequently, the spool is removed and can be stacked and transported without any further packaging steps.
The reusable NPS spool, which is used as a carrier system for the disposable NPS spools according to the embodiment, is described in reference to
The (carrier) spool 50, which is shown in
The second flange 54 is arranged at the end 52b of the winding core having the larger diameter and it is formed integrally with the winding core. The spool is in general substantially rotational symmetrically with respect to the axis 56 extending in the longitudinal direction.
On the second flange end, the fixed flange 54, reinforcing ribs 57 are provided, which increase the stability and rigidity of the flange. Further, a number of borings 59 are arranged in the flange, extending perpendicular to the axis of rotation 56. These borings can be used for use of lifting means or for the attachment of unwinding means.
As can be seen in
Since the end 52b of the winding core having the larger diameter is open, a conical cavity is created, which allows the stacking of the winding core.
As shown in
The winding core 52 and the flange 53 are manufactured separately from each other, preferably by an injection molding from a suitable plastic material. The winding core 52 and the flange 53 are assembled and then they can be wound using the conventional reusable NPS spool. As soon as the first wire windings have been laid around the spool core, a fixed form fitting connection is obtained between the winding core top 52 and the removable flange 53, which increases the stability of the connection. This means that the thickness of the winding core shell and the geometric arrangement of the snap in pins can be so selected that an assembling and a disassembling by hand is possible.
Additional safeguards, such as a screw locking and the like, are not required.
The assembly of the reusable NPS spool as the carrier spool is performed accordingly at the accommodating of the disposable NPS spools according to the embodiment as well as their removing from the reusable NPS spool.
Subsequently, two disposable NPS spools according to the embodiment are explained in regard to
The second flange 302 is arranged at the end 302b of the winding core top having the larger diameter and it is formed integrally with the winding core top 301. The disposable package 300 as a whole is substantially rotationally symmetrical in respect to the axis 305, which is extending in the longitudinal direction.
As shown in
The form and the arrangement of the latching borings 311, respectively are made in accordance with the segment latching 312, so that an easy obtainable engagement of the segment latching 312 can be achieved in the latching boring 311. At the same time, this engagement also prevents a rotation of the detachable flange 303 in regard to the winding core top 301.
As shown in
Further, a plurality of borings 421, so-called carrying eyes, are arranged in the flange, which are extending perpendicular to the axis 305 of rotation. The borings or the carrying eyes 421, respectively can be used for the use of the lifting means or for the attachment of the unwinding means.
As can be seen in
As can also be seen in
Further, the taper angle of the shell of the winding core top substantially coincides with the taper angle of the winding core of the spool carrier, whereby a frictional engagement is obtained at least in partial areas between the winding core of the disposable spool top and the winding core of the spool carrier. Cavities in between can be filled by soft materials.
Since the end 302b having the larger diameter of the winding core top is open, a conical cavity is created thereby, which allows the stacking of the winding core. As shown in
The conical extension 320 has inwardly pointed latching projections or segment latchings 312, 412, 912, 1012, whose engagement surfaces are extending substantially perpendicular to the cylinder axis 305, wherein this conical extension 320 is facing the winding core top 301 for the assembly. In the assembled state, the segment latchings 312 are engaged with the engagement boring 311 of the winding core top 301. The conical extension 320 is integrally connected with the rotationally symmetrical flange disk 321. As shown in
Further, the first detachable flange 303 has a tearing tab 840, which serves to open the circumferential latching. As can be seen in
Preferably, the distances x and y can be dimensioned such that the distance x 1090 is smaller than the distance y 1091. In this case, both latchings carry, whereby the forces are spread evenly and a lower wall thickness can be realized.
The function of this disposable spool is in accordance with the reusable spool as following:
The winding core top 301 and the flange 303 are manufactured separately, e.g., by an injection molding of a respective suitable plastic material, for example, PE and PP.
For the assembly of the spool, the flange 302 is placed on a flat surface and the end 302a of the winding core top is pressed on the conical extension 320. The segment latchings 312 of the flange 303 snap into the borings 311 of the winding core top 301. Then, the assembly of the disposable spool is completed.
The assembled disposable spool is mounted on a non-mounted reusable spool which subsequently is mounted as described in the above, however, and which as described—in this case, as the carrier of the disposable spool—is inserted into the winding device. Then, the winding of the disposable spool can be started.
As soon as the first windings of the wire have been laid around the winding core top 301, the segment latchings 312 are prevented from a moving to the outward direction. Thus, a firm positive connection between the winding core top 301 and the detachable flange 303 is achieved.
As can be seen in
Further, the disk has a centering 351, which can be brought into engagement with a corresponding recess 354 in the flange 3 of the reusable spool. Furthermore, the disk 350 has a free rotation 353 for the locking to be opened.
Corresponding to the illustration of
As shown in
Due to the construction according to some embodiments, even partially filled spools can be transported and stored. In
For the transport, an NPS spool is assembled. The other spools, which are to be transported, are disassembled. As shown in
By this, a small air gap can be formed, which minimizes the adhesion forces between the stacked winding core tops, so that the winding core tops can be separated from each other in a simple manner. As shown in
In
An alternative carrier system 1600 for the disposable NPS spool 1601 is shown in
An outer diameter 1603a of this rotationally symmetrical conical extension 1603 is dimensioned such that an outer wall 1603b of the extension 1603 contacts the inner wall 1606a of the winding core top 1606 in the area of the winding core top 1606 with the fixed flange 1607 and thus supports it. A second lower end 1608a of this cylindrical body 1605 also has a flange 1608b, to which a carrier plate or metal plate in 1609 is screwed.
These rotationally symmetrical flange support plate 1609 is correspondingly constructed being functionally equal to the above extension 1603, so that an outer wall of the support plate 1609a 16091610a contacts the circumferential latchings of the winding core top 1606 at the end of the detachable flange 1611, and thus supports it.
The support plate 1609 is constructed disk-like at one end. A thus formed surface 1612 supports the (mounted) detachable flange 1611 on its lower side 1611a. To avoid a rotation of the winding spool, which is mounted in the carrier system, a pin 1613 may be arranged.
The pocket-like recess is offset from the inner surface 2001e by the dimension k2, wherein the dimension k2 corresponds substantially to the wall thickness of the latching engagement 2013 in this area. By this adjustment in this area, the wall thickness t remains preserved in total and there it is obtained a continuous surface profile in the inner surface 2001e. Further, the pocket-like recess is offset from the front surface 2001d by the dimension k1, wherein the dimension k1 corresponds essentially to the wall thickness of the latching intrusion 2013 in this area. Here is obtained also a continuous surface profile in the surface 2001d. The hollow conical section also has additional the latching boring 2011, into which further (not shown) latching intrusions of the detachable flange 2003 can be engaged.
While the inventive technology has been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2012 024 450.9 | Dec 2012 | DE | national |
This application is a continuation application, and claims the benefit under 35 U.S.C. §§120 and 365 of PCT Application No. PCT/EP2013/003759, filed on Dec. 12, 2013, which is hereby incorporated by reference. PCT/EP2013/003759 also claimed priority from German Patent Application No. 10 2012 024 450.9 filed on Dec. 13, 2012, which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2013/003759 | Dec 2013 | US |
| Child | 14738588 | US |
