EP1853502B1

EP1853502B1 - Coiler for metallic rolled or drawn wires and/or bars with secure hooking

Info

Publication number: EP1853502B1
Application number: EP06706380A
Authority: EP
Inventors: Federico Castellani
Original assignee: SIMAC SpA
Current assignee: SIMAC SpA
Priority date: 2005-02-11
Filing date: 2006-01-24
Publication date: 2010-04-21
Anticipated expiration: 2026-01-24
Also published as: PL1853502T3; PT1853502E; ATE465115T1; DE602006013795D1; RU2007133825A; EP1853502A1; WO2006084574A1; ITUD20050017A1; ES2345941T3; CN101128378A

Abstract

Coiler (2) for metallic rolled or drawn wires and/or rods of material to be wound in a coil (T), of the type comprising a winding mandrel (25-253) that is reel shaped with an external flange (254) that can be opened for the extraction of the coil and a base counter-flange (251) carrying in an overhanging way said mandrel (253), associated to guide means of the material to be wound (1) and pressing guide means (232-233) for inserting and holding at least a part of the first turn of the material to be wound (Tl) in a recess adhering to the mandrel (253) and adjacent to said base flange (251), characterized in that said recess is defined between said mandrel (253) and a toothed rim (252) that projects from said base flange (251).

Description

Technical Field

The object of the present invention is a coiler for metallic rolled or drawn wire and/or rods with secure hooking, according to the characteristics of the main claim.
The winding installation and/or the production line of the material containing said coiler is also part of this invention.

Definition

Wires and/or rods are understood both in the strictest sense as well as in the sense of rods, namely material with a large diameter and/or profiles and/or sections with a varying form and shape that is to be wound in coils by means of a flanged rotating mandrel or reel, said coils then being removed and transferred to a binder machine.
Said wire and/or rods and/or profile and/or section can produced in a continuous or non-continuous way at various speeds both in rolling and drawing installations, but preferably, although not exclusively in continuous hot rolling installations
The definition of material or material to be wound is understood in this description as any type of elongated material as mentioned above.

Background Art

In the present state of the art different types of wire coilers are known, particularly those originating from continuous production installations of both rolled and drawn wire or rod.
In particular, high working speeds are required in the field of rolling and therefore the wire or rod is sectioned into determined lengths corresponding to a coil and is then redirected for winding on one coiler unit or on another, so that when a coiler winds the wire to form a coil, the other discharges the coil already completed.
One of the main problems with high speeds is the introduction of the wire into the coiler (also known as a winding machine or mandrel recoiler), which must take place while the wire advances without stopping the advancement of said wire.
At present there are different systems for the introduction and extraction of the end of the material to be wound in order to wind said material around the mandrel of the coiler with a slight tension so that a compact and well formed coil is produced, thanks to a light tension of the material during winding.
The introduction and clamping of the wire occurs by means of a guide channel capable of forming at least the first turn of the coil or a series of first turns.
US3592399 (Jul 13-1971 ), FR2057722 , GB1277515 , DE2027516 (MORGAN), describe a wire winding machine in which the coiler has an intake channel and forms the first turn (see description and also in particular Figs. 3, 4, 5, 6, 7) by using a semi-guide with a 180° arc of circle that allows the wire or bar that has been introduced to follow the form of the mandrel to wind itself up tightly and quickly around said mandrel.
US3945585 of 23 March 1976 (DEMAG) provides a channel for clamping and formation of the first turns of the coil around the mandrel by means of a bell type element that advances and retracts (10, 6, 11) precisely forming an entrance and clamping channel of the wire during the winding of the first turns.
US-4664329 (Pali-Essex - 12 May 1987) provides a wire guide and clamping system for the formation of the coil by means of a strip that winds the coil and simultaneously pulls it thus making the winding mandrel rotate, in this way the wire is continuously forced to wind itself compactly.
DE821666 (Siemens - 8 July 1049) describes different systems for guide channels and clamping of the wire/bar, for the formation of the coil around the mandrel / coiler reel. In particular, see description and Figures 1,2,3,4,5,6,7 that show different solutions for the guiding and the hooking or grasping of the end of the wire 3.
EP1126934 and EP1126935 (Danieli ) also describe wire guide systems for the start of the formation of the coil similar to Morgan.
The Italian patent applications UD2004A000006 , UD2004A000007 (Danieli ) to some extent concern the same solutions as the two previous solutions, wherein said wire/bar fixing channel is provided as well as the use of dynamically operating pincers to clamp the end of the material for the formation of the first turns.
In both in the DEMAG solutions and in the DANIELI solutions, a dynamic clamping system is provided with a pincer function of the wire that is then loosened (withdrawal in the DEMAG system) to allow the extraction of the coil from the winding mandrel at the end of winding.
In one known Danieli solution, the clamping system of the first turns of the wire is executed as in US3945585 (DEMAG) but with the movement of the entire base flange which moves along the mandrel making the wire intake channel deeper in order to allow the embedding of certain turns, to then be withdrawn covering only a part of the first turn when the return winding that forms the second layer is carried out. The solution is structurally very complex and also expensive in terms of the movement mechanisms required for a large mass such as the base flange.
In other solutions, provision is made for the simple following of the wire so that more turns themselves determine the clamping.
A characteristic repeated in the existing solutions is the intake guide for sliding the wire that occurs as mentioned by means of the form of the semicircular arc guide that due to friction forces the head of the wire in advancement to curve and wind itself around the mandrel ( WO2005/084843 ).

Drawbacks of the Existing solutions

The guide system having a fixed arched channel without rotating elements, presents the inconvenience of producing considerable friction and since the wire to be wound is still hot as it originates from hot rolling, it is notably very flexible and therefore could snarl and cause tangling, forcing the stoppage of the winding installation and as a consequence the entire production line.
Moreover, the use of this guide channel, that in Morgan has a 180° semicircular form and in Danieli covers the whole 360° turn of the mandrel by means of two opposite semicircles, creates significant problems in terms of temperature accumulation as this guide impedes the elimination of heat and wear since the material must slide against these guides.
The inconvenience residing in the fact that it also fails to guarantee the secure hooking or clamping of the material to be wound can lead to the unhooking of the wire introduced and therefore can lead to tangling and the need to interrupt production with the serious consequences deriving thereof.
In fact, it should be noted that the mandrel of the coiler must rotate at a peripheral speed slightly higher than that of the advancement of the material so that the latter is placed in slight tension in order to favour correct and compact winding.
However, this often causes the unhooking of the material just introduced and therefore the blockage of production. US3527077A (...NARGANG) also refers to coiling rod in which: "to assist in holding the inserted leading edge of the rod R, in the groove 136, serrations can be provided on the shoulder 118 and the inner periphery of the radial end face of the wall 126, as depitcted in Fig.3A):" In this solution it is suggested the use of an "U-grooved"sliding guide element (242) in prosecution of a free rotating bar clamping-roller (210 - Fig.3 particular: 3A-3A Fig.3 in connection with Fig.3A).
US3472461A (..FREDRIKSSON) discloses a "Method and apparatus for anchoring one end of the continuous advancing material" in which on a "carrier groove 12" of a "winding head 10" the "leading end 13 of the material being wound" is clamped by the "roller means (14) in the shape of sector".

Aim of this Invention

The main aim of this invention is to supply a much more effective and suitable system to guide and hook automatically the material to be wound without dynamic pincer systems and to limit to a minimum the damage to the wire when introduced.

Solution to the Problem and Summary of the Invention

The problem is solved with the characteristics of the main claim.
The sub-claims represent preferred embodiments of the invention. Advantages
In this way, by using a pressure counter-guide with rollers, friction is significantly reduced which thus renders rapid heat elimination possible and it is possible to press much more effectively the end of the wire to be introduced into the retention system of the first turn or part of it, therefore avoiding wear and damage to the wire itself.
Furthermore, thanks to the use of the rim of teeth placed at the base of the flange of the winding mandrel, slightly distanced from the mandrel itself in accordance with the diameter of the section of the material to be wound, that acts in cooperation with the counter-guide with opposite jaw-shaped rollers that pushes the intake material between the teeth, and the mandrel clamping said material like the precise action of a jaw, it is possible to obtain a perfect, secure and immediate hooking of the material without any danger of loosening and thus a perfect and fast formation of the coil without obstacles is guaranteed.
In fact, the grip jaw is substantially formed:

by the lower rim of teeth that rotates with the mandrel, with preferred counter-positioning of helical ribbings on the side of the mandrel,
by the semi-rim of upper rollers which are static, that is to say they do not rotate with respect to the mandrel, but rotationally are freely idle and therefore operate in the same manner as the upper teeth of the jaw but are stationary and rotate and therefore they oblige the advancing material to insert itself forcedly between the lower rim of teeth and the external surface of the mandrel.

The concept of the hooking system with a jaw having clamping teeth and the first formation of the turn, is therefore particularly effective precisely for the use of:

teeth and not in a channel as in the previous solutions, but on one side (lower) and
idle pressure rollers on the other (opposite upper side);
presence of helical ribbings or toothing opposite the said teeth forming said rim around the surface of the mandrel.

The invention also provides the use of interchangeable teeth allowing the coiler to be adapted easily to different types of wire or rods or sections and also different profiles, as otherwise it would also be necessary to change the winding machine, since the same channel would not be suitable for adapting to any form or profile of material to be wound.
Considering as an example, flat rolled sections or profiled sections or even smooth or ribbed bars with varying diameters, etc., the large variety of material to be wound originating, for example, from one rolling plant or from several separate rolling lines immediately becomes evident.
It is therefore highly useful to have a coiler capable of executing the winding of different forms of material, this also being associated with the intermediation of transfer means, generally to a binding machine downstream for the binding of the coil when completed.

Description of a Preferred Embodiment

The invention will be now better understood with the aid of the attached Figures including a particularly preferred, although not limitative, embodiment.
The Figures represent:

Fig.1 a schematic side elevational view from above of a winding unit comprising the coiler with a winding mandrel according to the present invention. In this position the winding mandrel presents the external upper flange in sectors (254) in a lowered position, namely horizontal (like petals of an open flower) namely in the winding position to form the coil of material.
Fig.2 represents a schematic view from above of the winding unit in Figure 1.
Fig.3 represents the enlarged view (in vertical axial section passing through the winding mandrel axis) of the hooking and clamping system of the end of the material and formation of the following turns.
Fig.4 represents the enlarged view as in Fig.3 from above of the winding mandrel with its respective rim of teeth for clamping of the material according to the invention.
Fig.5 represents the same view of Figure 4 in association with Fig.6 which represents in an enlarged view the form and arrangement of the teeth and represents how the wire or bar or rod (material to be wound) is tightly fitted between the teeth and the mandrel body, in this specific case the material to be wound (T1) takes the form of a ribbed bar, the material predominantly used in reinforced concrete structures in construction.

In this case, it is clear to see that the ribbings of the bar (T1) are inserted easily between the teeth (252) thus blocking the bar in a completely secure way, however this is also the case without said ribbings. Fig.6 represents a schematic view of the helical grip ribbings (2531) on the surface of the mandrel opposite the teeth (252), which decisively improves the grip and prevents the wire from escaping due to the internal traction of the helical grooves Figure 7 represents in a more enlarged view, the left part of Figure 3 to show in greater detail the pressing system with rollers (234, 2341) that progressively push and maintain the bar between said clamping teeth (252) and the mandrel (253).
Similarly, Figure 8 represents the enlarged right side of Figure 3 to show, not only the recessed arched form (2520) of the tooth (252) toward the mandrel, but also its inclined trapezoidal form towards the exterior (2521) in order to be tapered and prevent its height from exceeding the diameter of the bar (T1) in order to avoid obstructing the formation of the turns interposing between one turn and another, namely between the first row and the third row of turns of the coils.
In this way it is understood that the coil can easily be extracted axially when completed and the minimum space left by the toothing of the teeth (252) does not substantially influence its form, dimension or weight.

Detailed Description of the Figures

From the Figures it is observed that the winding unit includes a coiler (2) associated to motorization means (M, M1) for the rotation of its mandrel (25) and semicircular pressure means in the form of an open jaw (233) with pressure rollers (234, 2341) on an arm (232) that is hinged (230) and activated by means of a return lever (231) with a piston (23) articulated at the base (20) of the coiler (2).
In this way it comprises, as visible from the thin line, that the jaw with rollers (232,233), open towards the exterior, can be raised and lowered to press over a lower base flange (252) of the winding mandrel (253), that according to the invention presents the rim of teeth for holding material (252) and thus against these teeth.
The entrance of the wire is favoured by a funnel-shaped entry of the entrance side (235) of the jaw (233) that immediately presents a first pressure roller (234) that is more effective than other entrance solutions.
The articulation of the pressure jaw (232, ..., 32) is such that it is possible to transfer it from an engagement position of its rollers (234, 2340, 2341) against the rim of teeth (252), to a substantially distanced position, outside the material winding area, (to allow the approach of other series of opposite rollers (not illustrated) suitable for maintaining the winding of the last turns when the wire is not held in tension by the drive means, once the coil is completed, and this allows a grip and extraction of the coil without loosening the turns themselves).
The winding mandrel (253) rotates at a variable speed by means of the motor system (M, M1), placed downstream to the side of the jaw with rollers (233, 234). In this way the winding system is freed from any obstruction thus allowing other orthogonal counter-rollers to approach oppositely after engagement for maintenance of unwinding in the final winding phases.
The rotation speed is calculated in such a way that there is always the same peripheral speed corresponding to that of the linear advancement of the wire, the assembly being controlled by an electronic control unit distanced from the safety system so as not to be influenced by the temperatures that develop in the area of winding or coiling.
The mandrel consists of retractable sectors that in cooperation with lower and internal movement (255, 256) are withdrawn when the coil has been completed, being arranged conically in order to facilitate the upward extraction of the finished coil and the release of the wire head previously clamped.
Crosswise grooves (2510) are provided on the base flange (251) to allow the seizing of the coil with opposite gripper jaws for the extraction of the coil by means of lifting, said flange being integrated into the structure of the mandrel itself (2530) and therefore having a simplified structure without complex movement mechanisms.
In detail the mandrel (2530) is formed, as mentioned (although not shown) by four hinged sectors at the base of the flange (251), which tighten for the extraction and are also associated to a mechanism (not shown of rotation of the corresponding four upper flange sectors (254) that by means of the axis (255), and the movement devices below (257), of the unit (256) are raised like the petals of a flower and allow therefore the upward extraction of the coil (petals closed)).
Frontally to the coiler (2) there is a wire guide trolley (1) that comprises a horizontal guide (121) of the base (10) orthogonal to the medium advancing line of the material (X-X) on which a slide (11) is mounted with an auger column (111).
The slide (11) therefore moves alternately on command (not shown) in order to move the auger column (11-111) according to the axis (Y-Y) to always maintain it on course, namely on the tangent to the coil winding diameter of the mandrel (253), that noticeably increases progressively with the increase of the diameter of the coil in winding.
The auger column (11-111) moves vertically in a reciprocating movement (therefore alternately) a slide (110) that is thus raised and lowered according to the orthogonal axis (Z-Z) to form progressively the forward and return turn of the coil in winding.
For this purpose, the plate of the slide that is moved vertically (110), by the auger column (111) for left or right rotation by means of a known electromotor (for example, stepping controlled) and by a suitable electronic control unit that checks all the movements of the winding device, supports with hinges the end of a support or oscillating pilot bar (1131) that carries the material to be wound such as wire or rod or bar from the rolling mill with a suitable cutting system (not shown).
Said guide is hinged (1130) to said plate (110) to allow reciprocal inclination for the formation of the turns in the coiler (25).
The pilot bar support (11341) comprises the guide channel of the material (113) that presents a wire guide entrance extension (1130).
Immediately downstream of this guide channel (1130-113) there is an oscillating wire guide extension (112) which oscillates on a pin (1120) to keep the material in winding always according to the inclination angle, upwards once (with the wire guide extension in a downward movement) and downwards once (with the wire guide extension in an upward movement) so that the inclination always corresponds to the winding inclination angle of the wire wound on a bobbin that it is never orthogonal. The end of this oscillating wire-guide extension (112) can advantageously be interchangeable to adapt to the form of the type of material to be wound.
The advancing material thus exits the wire guide extension (112) and is introduced into the entry (235) of the jaw with guide rollers (233-234) where the material (T1) is progressively pressed by the rollers (234,2341) between the rim of teeth (252) and the external surface of the mandrel (253) clamping the material (T1) in a forced way.
In this way the material (T1) is blocked within the tooth rim (252) and the tensioning of the wire for the tight winding around the mandrel (25) is aided.
It will be noted that advantageously the first entry roller is slightly recessed (234-2340) in such a way as to aid the entrance of the material (T1), then the successive rollers are cylindrical (2341) to press the material (T1) definitively between the rim of teeth (252) and the external surface of the mandrel (253) until hitting the bottom of the base flange (251).
Of course, it would also be possible to supply convex or ribbed rollers at the end for the improved pushing of the wire or rod between the teeth in the final exit phase (end jaw).
The internal recessed arched form of the teeth (2520) aids the hooking of the material and hinders the escape of the material by favouring the housing.
The external trapezoidal form of the teeth (2520.252) allows improved housing of the following turns of the coil without hampering their staggered formation.
It is to be noted that the idle press rollers are mounted (233) on bearings (2331-2332) which in an overhanging way carry the axis (2342) of the rollers 234 that for this purpose have a flared inclined flanging (2342) that fits with the inclined trapezoidal surface (2521) of the teeth (252).
This improved support aids the controlled penetration in a precise way of the material to be wound. The roller overhanging toward the mandrel, moreover, allows its maximum approach to the mandrel with an improved wire guide.
Naturally, all the teeth (252), as mentioned earlier, are interchangeable with other suitable forms in order to adapt to the different forms and dimensions of the material to be wound.

The number of press rollers (234) can obviously vary most.

In order to improve holding it is also possible to provide projecting helical ribbings for gripping material, placed on the external surface (2531) corresponding to the mandrel (253) opposite the teeth (252).
Once the coil is finished the mandrel withdraws in its diameter assuming a conical form and consequently the clamped bar of the first winding turn is freed and therefore the upward extraction of the coil is aided.
Advantageously, the internal surface of said teeth (252) is ribbed and/or toothed and/or knurled. In this way an improved grip as on the opposite surface (2520) is guaranteed.
The interchangeability of said teeth is guaranteed by a fixing system passing through said base flange (251). In this way, the teeth can easily be interchanged when they are worn out or even for replacing them with other different types of teeth in order to adapt to different materials to be wound.
In order to avoid dangers and for safety reasons, the entire coiler is housed in a box made from sheet metal and suitable videocameras control its functioning from a remote television control room and it is associated to computerized means for the total control of functioning.
Advantageously, the coiler has a vertical axis (2) and is housed in an armour-plated box made from sheet metal closed with a safety access door that cannot be opened during functioning and that comprises an upper opening in order to be able to lower coil withdrawal means from above to be able to carry out extraction from above, and control means and sensors and a videocamera are provided in said box for the control and checking of the regular progression of the work by means of a cabin with remote control.
More advantageously a rolling plant is provided with these coilers, comprising at least two winding lines downstream, with a continuous cutting system and deviation on one or the other, parallel with identical coilers having a vertical axis (2) between which is interposed a vertical transfer extractor with a column with a rotary arm for extracting alternately from above the completed coil from a coiler while the other is forming a coil, and rotationally transfers it downstream directly in a coil binder machine.

Claims

Coiler (2) for rolled or drawn metallic wires and/or rods which is the material to be wound in a coil (T), of the type comprising a winding mandrel (25-253) in the form of a reel with an external flange (254) that can be opened for the extraction of the coil and a base counter-flange (251) carrying in an overhanging way said mandrel (253), associated with guiding means of the material to be wound (1) and pressing guiding means (232-233) for the insertion and holding of at least a part of the first turn of the material to be wound (T1) in a recess adhering to the mandrel (253) and adjacent to said base flange (251) characterized in that said recess is defined between said mandrel (253-2531) and a rim of teeth (252) that projects from said base flange (251) and in that said pressing guide means (232-233) present a series of press rollers (234, 2341) that can move from a pressure position over said teeth (252) to press the material to be wound (T1) between said teeth (252) and said mandrel (253), to a position substantially distanced from it.
Coiler (2) according to the previous claim, characterized in that said pressing guide means with rollers (234-2341) are:
(i) rotationally idle

(ii) mounted on a circular support (233) with an arm (232) hinged on the axis (230) placed downstream on the opposite side to the wire guide system (1) and in which the hinging axis (230) is substantially orthogonal to the advancement line and in orthogonal projection to the mandrel axis, in such a way that said circular guide means with press rollers (233,234,2341):
- in the rest position are raised and withdrawn substantially distanced downstream with respect to the material supply line, and

- in the active position, advance by leaning on said rim of teeth (252) with a radial axis with respect to the mandrel axis.
Coiler (2) according to the previous claim, characterized in that on the internal surface opposite to the said rim of teeth (252), substantially on the mandrel side (253), ribbings or gripper teeth (2531) are provided.
Coiler (2) according to the previous claim, characterized in that said ribbings or gripper teeth (2531) have a substantially helicoidal course or in any case inclined in order to move progressively toward the bottom flange with respect to the direction of rotation, in order to force the material inserted that is to be wound (T1), pushed by the said rolls (234, 23341) to move by sliding, due to the traction of the mandrel, even more so in said recess within said rim of teeth (252).
Coiler (2) according to any of the previous claims, characterized in that at least the first entrance roller (34) of said jaw (233) presents a recessed form to forward (2340) the material to be inserted (T1) and is placed substantially adjacent to a wire entry zone (235).
Coiler (2) according to any of the previous claims, characterized in that at least some of said press rollers (34) have a cylindrical shape (2341).
Coiler (2) according to any of the previous claims, characterized in that said teeth (252) are interchangeable.
Coiler (2) according to any of the previous claims, characterized in that said teeth (252) have a recess directed inwards (2520), namely on the mandrel side (253).
Coiler (2) according to any of the previous claims, characterized in that said teeth (252) have a bevelled back with truncated cone towards the exterior (2521), namely on the opposite side to the mandrel (253).
Coiler (2) according to any of the previous claims, characterized in that said teeth (252) have a projection that does not exceed the diameter of the material to be wound (T1).
Coiler (2) according to any of the previous claims, characterized in that said teeth (252) are placed on said base flange (251) with an axis substantially corresponding to the position of the second row of turns of the coil in winding (T-T1), in such a way that they are embedded between the first row of the turns and the third row of the turns of the coil.
Coiler (2) according to any of the previous claims, characterized in that the internal surface (2520) of said teeth (252) is ribbed and/or toothed and/or knurled.
Coiler (2) according to any of the previous claims, characterized in that said rollers have a rebated flange (2342) suitable for support during rolling against said inclined external back surface (2521) of said teeth.
Coiler (2) according to any of the previous claims, characterized in that said press rollers (234, 2341) are mounted in an overhanging way (2343) and in an operating position projecting inwardly, namely towards the axis of the mandrel (253).
Coiler with vertical axis (2) according to any of the previous claims,
characterized in that it is housed in an armoured box made from sheet metal closed with a safety access door that cannot be opened during functioning and comprising an upper opening in order to be able to lower from above coil withdrawal means for extraction from above, with control and sensor means and a videocamera being associated to said box for the control and checking of the regular execution of the work by means of a remote control cabin.
Rod or wire coil formation plant associated to coil transfer and coil binding means comprising at least one coiler according to any of the previous claims from 1 to 9.
Rolling plant comprising at least one coiler (2) according to any of the previous claims.
Rolling plant according to the previous claim, comprising at least two winding lines downstream, with a continuous cutting system and deviation on one or the other, parallel with coilers with vertical axis (2) according to any of the previous claims between which is interposed a vertical transfer extractor with a column with a rotary arm for withdrawal alternately from above of the completed coil from a coiler while the other is forming a coil and rotationally transfers it downstream directly in a coil binder machine.