EP0029971B1 - Method for winding wire on wire holders, and wire holder for taking up the wire - Google Patents

Description

The invention relates to a method for winding wires on a wire carrier with a conical core, for the sake of simplicity also referred to as a coil, on which the wire is wound in layers using a flyer until it has reached the maximum winding diameter.

According to the prior art, the wires are wound on coils with a cylindrical core, and the resulting wire bundle accordingly has cylindrical wire layers.

Coils with a slightly conical core are also known. However, the wire is wound onto these coils in slightly conical layers and, if necessary, wound into a cylindrical shape. These coils are mainly used for winding lacquered wires, which during the subsequent winding operations are wound up from the outside inward at relatively high speeds from these coils overhead. The taper serves the purpose of preventing the wire layers from trickling down when the spool is stationary and offers the possibility of using a smaller spool diameter on the take-off side, which makes it easier to pull off the head.

In the case of very thick wires, which are, for example, in a diameter range of approximately 8 mm, it is also known if the coils are designed to be divisible, to remove the coil after the winding-up process and to unwind it from the inside out.

The winding of the wire in cylindrical layers has the disadvantage that the wire turns of one layer all have the same diameter. As the coils loosen during unwinding, there is a risk that they will fall down and slide over one another, which inevitably leads to confusion of the wire and thus to wire breaks.

This is particularly so because in most cases the coils or wire bundles are arranged in such a way that the winding axis is vertical or almost vertical when unwinding.

When unwinding cylindrically wound wire bundles there is also the disadvantage that if the wire package has been unwound so far that only a few wire layers are left, they collapse due to insufficient cohesion, become confused and can therefore no longer be used up. This means that this wire residue can no longer be sent to further processing and is generated as scrap.

In addition, the continuous operation desired for economical further processing is not possible.

In addition to the difficulties already mentioned, there is the problem that when unwinding from the inside to the outside due to the existing winding tensions, wire windings that are to be pulled off are pinched by the next wire layer. This also leads to wire breaks, particularly in the case of thin wires.

According to French patent specification 1,480,285, it is known to wind threads in layers on a spool with a conical core, the larger diameter end of the core initially being arranged at the bottom. The full spool is then turned over so that the larger diameter end of the core is now at the top. The upper bobbin flange is now removed together with the core, and a sleeve is pushed over the thread ball or the thread roll, which has a hole in the top center through which the thread can be pulled out of the ball. When pulling out the thread, the upper turns are always supported on a lower turn of smaller diameter, so that the turns are prevented from slipping when the thread is pulled out.

The winding of wires on a spool with the help of a flyer is therefore carried out in order to be able to wind a lot of wire on the spool without moving large masses. As a result, the further processing process can run continuously over a long period of time until the end of the wire of the first coil has to be connected to the beginning of the wire of the next coil. Such coils covered with wire are very heavy. An interim reversal of the full spool, as required by French patent 1,480,285, would therefore require a great deal of work and special technical means in transferring the invention.

The object of the invention is to provide a method for winding wires in a conical position, in which the wire is wound from the outset, so that it can then be removed from or from the container without any additional work step.

This object is achieved by the winding process of the characterizing part of claim 1.

The winding of a wire using a flyer is known from US Pat. No. 2,709,553. Here, however, the flyer is used to impose a forced twist on the originally tangentially wound wire, so that it can be removed from the coil without twisting after rewinding.

According to the invention, the flyer is used for winding the wire in layers on the spool, by rotating the flyer rollers around the spool and moving them up and down for the purpose of laying the wire.

The wire is pulled off through the opening having the larger diameter, that is to say upwards from the inside of the container. For this you can remove the upper coil flange and the core and pull the wire out of the funnel-shaped opening.

However, removing the core during further processing is not mandatory. It is sufficient to move the core in the axial direction so that a gap is created between the core and the innermost wire layer, through which the wire is pulled out of the container.

In order to pull off the wire, the coil axis or the axis of the container need not be arranged vertically if thicker wires have been wound up. Due to the inherent tension, the windings remain in their place in this case even if the container is aligned with its axis, for example horizontally.

In principle, the choice of the taper of the wire layers or the coil core is arbitrary. However, they can be optimally designed depending on the thickness of the wire and the winding diameter.

Due to the taper of the wire layers, the running speed of the wire changes when winding each individual layer. For this reason, control measures are provided to keep the running speed of the wire constant.

For this purpose, the control means can additionally set the spool in rotation and regulate the speed of the flyer and / or the spool so that the running speed of the wire remains constant. To keep the running speed constant, a so-called breathing memory can also be provided in addition or on its own, which compensates for the change in running speed by changing the contents of the memory.

The measuring and control device advantageously responds to the speed of the coil and / or the flyer or to the tensile force of the wire during the winding process.

At the end of each wire layer, the wire laying device reverses its running direction. Since, according to the invention, when the maximum winding diameter is reached for the first time, the wrapping is then carried out in shortened layers in order to obtain an outer cylindrical shape of the container, one advantageously senses the reaching of the maximum winding diameter, for example optically.

The coil on which the wire is wound may have a conical core. However, it is also possible to use a commercially available divisible coil with a cylindrical core, over which a conical sleeve is pushed, which is then suitably fastened to the core or the flanges of the coil.

Since the wire is wound up using a flyer, the core only has to endure the winding pressure. The core can therefore be made of cardboard or a solid cardboard box, as can the flanges.

The wire container can be transported with or without a wire carrier. In both cases, it can be advantageous to protect the wire against corrosion or other influences by packaging made of paper, plastic, cardboard or the like. If the container is transported without a wire carrier, it is necessary to secure it against slipping of the individual wire layers or turns. This can be done either by tying the wire bundle by means of plastic, steel or the like, or by shrink-wrapping the wire package with a suitable plastic film. Another variant is to maintain or insert a conical core sleeve, which can advantageously be made of cardboard or the like. In these cases, shrink packaging or cardboard packaging is again suitable. Expediently, packaging and transport means are selected or designed in such a way that they represent, in whole or in part, the wire carrier for the winding and the necessary device for the unwinding.

For example, it is possible to fasten the conical core sleeve made of cardboard, plastic or the like on a Euro pallet together with the outer packaging, which can be made of cardboard, with a fixed or removable upper limiting disk. This unit is then inserted into a winding device, the wire being wound up using a rotating flyer. The outer packaging jacket is located underneath the wire package during the winding process and is then pulled up or folded up over the wire bundle and closed at the top. However, it is also possible to arrange only the take-up sleeve with the upper limiting disk on the pallet and then to push the packaging jacket over the wire container from above, to wrap around the wire container, to shrink it or to transport it without the outer packaging.

Since the upper coil flange is removed to pull off the wire, the edge turns are exposed here. In order that these turns are not entrained when the wire is pulled out, in a further embodiment of the invention an annular plate is placed on these turns, which, due to its own weight, prevents the upper turns from being pulled up, or a plate which is jammed with the lower support or other suitable means .

The plate itself can also be formed by the upper part of a packaging box, which, however, should then have a wear-resistant ring or the like, so that the wire does not cut into the edge of the box when it is pulled out.

Further details of the invention can be found in the subclaims and the following description of the drawing.

• Figur 1 eine Darstellung des Wickelvorganges ;
• Figur 2 einen Schnitt durch eine vollgewickelte Spule ;
• Figur 3 ein Drahtgebinde ohne Spule ;
• Figur 4 eine schematische Darstellung des Abwickelvorganges ;
• Figur 5 die Draufsicht auf die Fig. 4 ;
• Figur 6 ein verpacktes Drahtgebinde in Seitenansicht ;
• Figur 7 die Draufsicht auf die Fig. 6 ;
• Figur 8 eine Darstellung des Abwickelvorganges bei Verwendung von zwei Drahtgebinden im kontinuierlichen Betrieb ;
• Figur 9 die Draufsicht auf die Fig. 8.

Show it :

• Figure 1 is an illustration of the winding process;
• Figure 2 shows a section through a fully wound coil;
• 3 shows a wire container without a coil;
• Figure 4 is a schematic representation of the unwinding process;
• 5 shows the top view of FIG. 4;
• Figure 6 shows a packaged wire container in side view;
• FIG. 7 shows the top view of FIG. 6;
• Figure 8 is an illustration of the unwinding process when using two wire packages in continuous operation;
• 9 shows the top view of FIG. 8.

1, a wire 3 is wound up in layers on a coil 1 which has a conical core 2. The innermost layer 4 lies against the core between the coil flanges 10 and 11 and therefore also has a conical shape. The next layer 5 lies on the layer 4 and therefore again has a conical shape. The wire is wound between the flanges 10 and 11 of the coil 1 in this way until the line 6 has been reached, at which the wire has approximately reached the outer edge of the coil flange 11. From here, the wire is wound in shortened layers, but still conically, until the container, as indicated by line 7, has assumed a cylindrical shape on the outside.

In the winding process according to the invention, the larger core diameter of the coil is at the top, and the wire is wound onto the coil by a flyer arranged axially above the coil.

Fig. 2 shows the coil 1 fully covered with wire. It can be seen that the radius of the wire turns changes from turn to turn in each wire layer. This results in considerable fluctuations in the running speed of the wire with a constant running speed of the coil or the flyer. In order to compensate for these fluctuations, known measuring and control devices (not shown) can be provided which either regulate the running speed or temporarily store the wire in a magazine known per se.

When using a wire storage device, the coil or the flyer rotates at a speed that corresponds to the wire speed of the wire layer to be wound in the middle between the two limiting flanges of the wire carrier. When a wire layer is further wound in the direction of a decreasing winding diameter, less wire is taken up by the coil, while wire is delivered by the drawing machine or other upstream devices at a constant speed. During this phase, the wire that is not taken up by the coil is taken up by a magazine that has a variable capacity. If the middle point between the limiting flanges is exceeded when the next wire layer is wound towards the increasing winding diameter, more wire is taken up by the coil than is supplied by the upstream devices. This additional wire requirement is now compensated for by the fact that the wire accumulation in the magazine is reduced again. This process is repeated with every wire layer. The basically required speed reduction due to the increase in winding diameter due to each wound wire layer can be done in a conventional manner by a controllable drive.

Both measures will advantageously be provided according to the invention, because particularly strong changes in running speed occur in the conical winding, i.e. via a controllable drive for the wire carrier or the flyer, both the required speed reduction due to the constant winding diameter increase and the partial compensation when winding a wire layer due to the conical winding surface causes. In order to keep the speed differences between the largest and smallest winding diameter of a wire layer within limits, the balancing effect of a so-called breathing memory described above is superimposed.

Fig. 3 shows a wire container, in which the coil with the core has been removed. The wire container has been shrink-wrapped with the aid of a film 12, either all around or without the conical inner opening. In the latter case, a cardboard sleeve 13 will be pushed into the interior of the container in order to give the inner wire layer a secure hold for transport purposes and to use the core sleeve as a wire guide funnel during unwinding. A core sleeve can also be used with shrink wrapping on all sides.

The end piece 15 of the wire has been placed from the last turn 16 around the outside of the wire container and then also introduced into the interior of the container, so that a wire supply 17 is also present here. The wire supply 17 can also be wrapped around the bundle in several windings. This wire end 17 is welded to the starting piece of a new container during further processing of the wire in order to ensure continuous further processing of the wire.

Fig. 4 shows the further processing of the wire in a schematic representation. The end piece 17 of the wire has been welded to the start piece 19 of another container at point 18. The starting piece 14 of the wire is pulled up out of the container. For this purpose, either the upper coil flange 11 together with the core 2 can be pulled out of the container. It must be detached from the lower coil flange 10. If the container was shrink-wrapped, it is sufficient to simply remove this packaging.

4, the core 2 is connected to the lower coil flange 10 with the aid of a bellows 20, so that it can be moved slightly in the direction of the arrow 21.

The ability to move and attach the core sleeve for the purpose of displaying a Wire guide gap can also be done in another suitable manner.

This displacement creates a space 22 between the core 2 and the innermost layer 4 of the wire, through which the wire 3 is drawn off.

The conical core sleeve can also be present at the further processing location and can be used before the unwinding process begins in such a way that the gap 22 shown in FIG. 4 is formed.

The sleeve used in this way serves as a guide funnel for the wire and prevents entire wire turns from being pulled out of the collar or that wire turns contract and form loops which lead to wire breaks.

The wire peels off in layers, i.e. H. the gap 22 becomes larger after each stripped layer and the wire supply correspondingly smaller. If the outer cylindrical edge of the wire container is reached, the height of the wire container will also decrease from layer to layer.

A plate 24 is placed on these windings so that the upper wire turns 23 are not carried away when pulling off. This can act through its own weight or a lighter plate can be connected in a modified version to the lower flange 10 with the aid of a clamping device. As can be seen from FIG. 5, the plate 24 is annular and can have a slot 25.

It is extremely advantageous not to interrupt the work process during further processing by replacing the used wire container with a new one when a wire container has been used up. Therefore, a continuous unwinding process is advantageously provided. For this purpose, two wire containers are set up at the unwinding station according to FIG. 8. Both wire containers are provided with a cover ring 50, 51, each of which contains a passage slot 52, 53 for the wire on the opposite side. During the normal unwinding process, it is advantageous to close these through slots in such a way that a closed, smooth inner ring results, since there is otherwise the risk that the wire will be damaged at this point. At the time of transferring the wire from the used to the full wire bundle, both slots are opened and immediately closed again. 8, the left bundle of wires is currently being unwound. The end of this collar is led up inside the outer shell and connected to the beginning of the right wire bundle by welding or the like. As soon as the last wire turn of the left bundle is pulled out, the wire inevitably runs through the then opened slot in the left cover ring and through the guide slot 54 provided between the two cover rings into the interior of the right bundle of wires, and the wire is then further removed there. During the unwinding process for the right bundle, a new wire bundle is set up on the left side, the beginning of which is connected in the opposite manner to the end 37 of the right bundle of wire that has already been brought out. If the right wire bundle is used up, transfer to the left side in the same way.

Another variant with regard to continuous operation is to move the complete cover ring to the full wire container with the last wire winding of the used wire bundle and to place it there for further covering. In this case the cover ring has no slot. The start and end of the wire are connected in the manner illustrated with reference to FIG. 8 and as described there.

6 and 7 show an embodiment in which the container 30 is arranged on a euro pallet 31. The lower flange 32 of a coil is fixedly arranged on the euro pallet, for example glued or screwed, or the pallet itself forms the lower limit for the wire package. At the same time, the euro pallet 31 carries a hexagon-shaped sleeve 33 fastened to it, which serves as packaging for the wire container. The outer packaging sleeve can be designed such that it is unfolded during the winding-up process in the lower level of the pallet, as shown in FIG. 6 with the position 36 in broken lines. In order to reduce or prevent the packaging from protruding beyond the edge of the pallet in this state, this outer sleeve can advantageously be designed to be foldable. The packaging sleeve with the top cover 34 can also be pushed over the wire container from above and fastened to the bottom of the pallet after the winding process.

At the top, the container is covered with hinged lids 34, which carry a reinforced edge 35, over which the wire can be pulled off. The lid can also consist of one piece. The cover 34 and the reinforcing edge 35 replace the plate 24 according to FIG. 4 in this embodiment.

Instead of the reinforcement edge, a wear-resistant ring can also be pushed over the edge of the lid before further processing of the wire.

Claims (29)

1. Method for winding wire on wire holders (coil (1)) with conical core (2), upon which the wire is wound in layers using a flyer, until it has reached the maximum winding diameter, characterized in that in the case of vertically arranged coil axis, overhead larger core diameter and coaxial arrangement of the flyer, the wire subsequently is wound in shortened conical layers so that an outer cylindrical shape for the bunch (skein) results.

2. Method according to claim 1, characterized in that the coil rotates additionally when winding up the wire.

3. Method according to claim 1 or claim 2, characterized in that when winding the wire the running speed of the wire is kept constant by speed variation of the flyer and/or the coil.

4. Method according to one of claims 1 through 3, characterized in that the fed wire, for keeping its running speed constant, runs through a changeable socalled « atmender Speicher (« breathing store"), by which variations of the circumferential speed of the winding surface are compensated by altering the contents of the store.

5. Method according to claim 1, characterized by the utilization of a measuring and control device, which is effective to reverse the running direction of the wire laying device after the maximum winding diameter is reached in each case.

6. Method according to claim 5, characterized in that the measuring and control device optically senses the maximum winding diameter.

7. Method according to claim 5, characterized in that the measuring and control device functions in response to the speed of the coil and/or the flyer or to the tensile force of the wire in the winding up operation.

8. Method according to claim 1, characterized in that the coil is fastened on a pallet, for example a Europallet (31).

9. Coil for carrying out the method according to claim 1, characterized in that the core in the bunch is slidable in axial direction by a determined amount so that a gap is provided between same and the innermost wire layer of the bunch, through which gap the wire may be drawn out of the bunch.

10. Coil according to claim 9, characterized in that between the core (2) and the flange (10), abutting the smaller diameter end of the core, connection means, elastical by a determined amount, preferably kind of a communication bellows (20), or the like, are provided between flange (10) and core (2).

11. Coil according to claim 9, characterized in that the core, possibly the whole coil, consists of cardboard, firm paperboard, wood, plastic material, or the like.

12. Method according to claim 1 or claim 8, characterized in that the bunch is encased.

13. Method according to claim 12, characterized in that the bunch is shrink-wrapped all around by means of a plastic material film, or the like.

14. Method according to claim 1 or claim 12, characterized in that, after the winding, the core is removed and is replaced by a conical cardboard sleeve (30).

15. Method according to claim 12, characterized in that the encasing is made of cardboard.

16. Method according to claim 1, characterized in that for the further processing of the wire the coil core together with the flange abutting the larger diameter-end of the core is drawn out of the wire bunch.

17. Method according to claim 1, characterized in that for the further processing of the wire the flange abutting the larger diameter-end of the core is removed, that the core is axially displaced so that between the core and the innermost wire layer of the bunch a gap is provided, and that the wire is drawn out of the bunch through this gap.

18. Method according to claim 16 or claim 17, characterized in that an annular plate (24), or the like, is placed on the exposed windings at the end of the bunch.

19. Method according to claim 18, characterized in that a heavy, in weight respect, plate (24) is used.

20. Method according to claim 18, characterized in that the plate (24) is locked with the remaining coil flange.

21. Method according to claim 19, characterized by the utilization of a plate (24) with a radial or approximatively radial slot (25), through which the wire end of the bunch is drawn in the continuous operation.

22. Method according to claim 18, characterized by the utilization of a closable slot, which in the closed condition secures an annular outlet for the discharge of the wire.

23. Method according to claim 18, characterized in that the plate is moved from one bunch to the next bunch in the continuous operation.

24. Method according to claim 18, characterized in that the plate is formed by a part (34) of a packing carton.

25. Method according to claim 24, characterized in that the wire runs over a wear-resisting ring (35) when drawn off, which is part of the packing carton.

26. Method according to claim 25, characterized in that the wear-resisiting ring is subsequently placed or pushed on the carton wall.

27. Method according to claim 1, characterized by the utilization of a conical core sleeve consisting of cardboard, plastic material, or the like, with a fixed or removable limiting disc, as well as in that possibly the core with the outer packing means, such as a carton, is fastened on a plate, particularly a Europallet.

28. Method according to claim 27, characterized in that the outer packing means, during the winding-up operation, are drawn downwards or are folded downwards and, after the winding-up operation, are drawn back upwards or are folded upwards, in order to be closed then at the upper side.

29. Method according to claim 12, characterized in that the packing encasing is pushed over the bunch after the winding-up operation.

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