EP4717619A1

EP4717619A1 - Operational drum filler for winding a filiform element inside an industrial drum

Info

Publication number: EP4717619A1
Application number: EP25204279.1A
Authority: EP
Inventors: Gianluca MARANGONI
Original assignee: Gimax Srl
Current assignee: Gimax Srl
Priority date: 2024-09-26
Filing date: 2025-09-24
Publication date: 2026-04-01

Abstract

An operational drum filler (1; 50) for winding a filiform element (F) inside an industrial drum (T) comprising a support framework (2; 51) which rest on a support surface (S) and is arranged downstream of an unwinding unit that unwinds a filiform element (F) from a reel wound around a flanged roller (L), pulling and dragging means (3) coupled to the support framework (2; 51) and configured to exert traction on the filiform element (F); returning and direction means (4), coupled to the support framework (2; 51) and arranged operatively downstream of the pulling and dragging means (3) from which they receive the filiform element (F); a base platform (5) coupled to a lower part (2a) of the support framework (2; 51) and configured to house in stable support an industrial drum (T) suitable to receive the filiform element (F) wrapped inside along a prefixed configuration; depositing means (6) arranged above the base platform (5) and configured to convey and release the filiform element (F) inside the industrial drum (T) forming a skein, and first actuation means (7), coupled to the support framework (2; 51) and suitable to automatically move at least the pulling and dragging means (3), the returning and direction means (4) and the depositing means (6). In particular, the operational drum filler (1; 50) comprises a loading station (8; 57), defined in the support framework (2; 51) where it is accessible to an operator (P) and distinct from the base platform (5), configured to house one or more of the industrial drums (T) still empty and to be filled with the filiform element (F) and operatively connected to second actuation means (9) coupled to the support framework (2; 51) and suitable to automatically move one after the other the industrial drums (F) still empty towards the base platform (5).

Description

The invention described herein concerns a drum filler (also known as a skeining machine or, more generally, a filling winding machine or apparatus, preferably fully or integrally automatic) used to wind (in a so-called "rosette" configuration) a pre-twisted thread-like element, such as welding wire, low-carbon steel wire, stainless steel wire, single-core wire, aluminum wire, electrical cable or 3D printer filament, into a drum, basket, or, more generally, a hollow industrial, for instance cylindrical, container.
In other words, the drum filler of the invention is used to fill an industrial container with a filiform element that is wound inside the container by one of the essential components of the drum filler itself.
Specifically, in this type of industrial machine of the invention, the wire is progressively wound in adjacent and overlapping (or stacked) coils in multiple layers within the hollow industrial drum, basket, drum, or container, thus obtaining a skein of wire to be intended for the subsequent related uses.
As known, the transport of filiform elements, such as metal wires used in industrial fields (for example welding wires, low-carbon wires, stainless steel wires, core wires, or aluminum wires), electrical cables, and similar items to a delivery facility occurs through industrial containers or drums, within which the filiform elements are ring-wound.
The operating machine used to wind the filiform element inside the industrial drum, also known in the technical jargon of the sector as a "drum filler," progressively deposits the filiform element inside the drum, winding it into a ring and presents a structure can be essentially divided into two parts:

a fixed part containing the components for moving the filiform element coming from an unwinder located upstream the drum filler, components which include, in detail, pulling and dragging means of the filiform element - such as a swivelling roller (or rotating inlet drum) and the capstan mounted along a horizontal axis - and straightening and direction means of the filiform element; the fixed part also houses the depositing device, known in the jargon as a "flyer," which, through a rotational motion, releases in wound way the filiform element inside the industrial drum beneath;
a vertically movable part, specifically comprising a base platform that is cantilevered installed onto the support framework and upon which the industrial drum to be filled with the wound wire is positioned.

The industrial drum is rotated around a vertical axis eccentrically with respect to the vertical rotation axis around which the flyer rotates, thus generating the deposit of the filiform element inside the drum in the form of a partly irregular ring since the winding of the filiform element takes a configuration known as a "rose" or "rosette"
(it is also known as "rosetting" of the filiform element, meaning the winding of the filiform element into a rosette shape).
From an operative perspective, at the start of the winding process, the base platform on which the empty industrial drum is placed automatically lifts, controlled by a sensor, such as for instance a photocell, located laterally with respect to the flyer, until the bottom of the industrial drum almost touches the bottom of the flyer. The operating drum filler then provides for the rotation of the flyer, from which the filiform element emerges to be wound inside the industrial drum, while the base platform slowly descends, as the ring of filiform element wound inside the drum increases in thickness, again controlled by the aforementioned sensor.
It should be noted that, at this stage, the regular compaction of the filiform element during the winding process inside the industrial drum is ensured by a vibrating device, generally installed at the bottom of the base platform.
Once the filiform element has been wound, the base platform, with the ring inside it having reached its maximum thickness, is positioned so as to lower completely and align itself with an unloading station where the industrial drum, loaded with the wound filiform element, is accessible to the operator for manual removal and its subsequent use, with possible but usual prior storage in a finished product warehouse and/or transport on suitable vehicle.
At the light of the above, albeit briefly, it is clear that the efficiency of nowadays commercially available drum fillers has reached high levels, but still not optimal and thus improvable, mainly considering that the loading phase of the empty industrial drum (to be filled with the skein of filiform element) is performed manually by an operator who places the drums one by one the vibrating base platform, beneath the flyer.
This inevitably limits the efficiency of the known operational drum fillers examined here, as well as their production cost, which, due to the labor required to load the empty industrial drum, is in any case high in relative terms (assuming a specific standard value for the cost of labor itself).
Therefore, starting from an awareness of the aforementioned limitations of the prior art, the present invention aims to effectively overcome them.
More in particular, primary purpose of the invention is to provide an operational drum filler for winding a filiform element inside an industrial drum which features a level of automation higher than the equivalent industrial drum fillers of known type. Within this first purpose, it's task of the current invention to provide an operational drum filler for winding a filiform element into a skein inside an industrial drum that features an efficiency higher than that of comparable operational drum fillers.
It is another task of the invention to indicate a drum filler for winding a filiform element into a skein inside an industrial drum which allows to reduce the costs relating to its functioning.
A last but not least purpose of the present invention is to design a drum filler for winding a filiform element inside an industrial drum that requires labor lower than prior art drum fillers, thus freeing it for other activities in a production facility.
Said purposes are achieved through a drum filler for winding a filiform element (such as a metal welding wire, a small electrical cable, or a 3D printer filament) into a skein inside an industrial drum, as per the attached claim 1, to which reference is made for the sake of brevity.
Further, non-limiting and non-completing, technical construction features of detail of the drum filler for winding a filiform element into a skein inside an industrial drum of the present invention are contained in the relative dependent claims.
The aforementioned claims, specifically and concretely defined below, are to be considered an integral part of this specification.
Advantageously, the drum filler of the present invention is more automated than similar drum fillers, greatly enhancing its performance, operating costs, and labor management within an industrial facility.
This is advantageously thanks to the fact that the operational drum filler of the present invention includes a loading station, defined in the support framework where it is accessible to an operator, distinct from the base platform and configured to house one or more industrial drums still empty and to be subsequently filled with the wound filiform element and operatively connected to second actuation means coupled to the support framework and in turn configured to automatically move one after the other the still empty industrial drums towards the base platform.
Even advantageously, thanks to the greater level of automation that distinguishes the operational drum filler of the invention compared to similar prior art, it is possible for a company, especially in the long term, to reduce labor costs or increase their efficiency, being able to allocate the same, even temporarily, to other tasks according to a management system that is currently not permitted.
Said purposes and advantages, as well as others that will emerge in the course of the paper, will appear more evident from the following description, relating to preferred embodiments of the operational drum filler, generally totally automatic, of the invention used for winding a filiform element into a skein inside an industrial drum, given for indicative and illustrative, but not limitative, purposes with the aid of the attached drawing tables in which:

figure 1 is a simplified assonometric view of a first possible embodiment of the operational drum filler of the invention, in a first operating condition;
figure 2 is an enlarged assonometric view of a construction assembly of the operational drum filler of figure 1, in a second operating condition, subsequent to the first operating condition;
figure 3 is an enlarged assonometric view of a further construction assembly of the operational drum filler of figure 1, in a third operating condition, subsequent to the first operating condition and the second operating condition;
figure 4 is a simplified assonometric view of a second possible embodiment of the operational drum filler of the invention, in a first operating condition;
figure 5 is an enlarged assonometric view of a construction assembly of the operational drum filler of figure 4, in a second operating condition, subsequent to the first operating condition;
figure 6 is an enlarged assonometric view of a further construction assembly of the operating drum filler of figure 4, in a third operating condition, subsequent to the first operating condition and the second operating condition.

The operational, usually automatic, drum filler for winding a filiform element inside an industrial drum, object of the present invention, is shown in a first conceptual solution in figure 1, where it is globally indicated by reference numeral 1.
It should be noted that the operational drum filler 1 for winding a pre-twisted filiform element F into a skein inside an industrial, typically cylindrical or frusto-conical in shape, drum T comprises:

a support framework 2 suitable to rest on a support surface S, such as the flooring of an industrial plant, and arranged downstream of an unwinding unit (not visible in figure 1) that unwinds a filiform element F from a reel wound around a flanged roller;
pulling and dragging means, collectively indicated by 3, coupled to the support framework 2 and configured to exert traction on the filiform element F;
returning and direction means, as a whole indicated with 4, coupled to the support framework 2 and operatively arranged downstream of the pulling and dragging means 3 from which they receive the filiform element F;
a base platform 5 coupled to a lower part 2a of the support framework 2 and configured to house, in stable support, an industrial drum T suitable to receive the filiform element F wrapped inside according to a prefixed configuration;
depositing means, collectively numbered by 6, arranged above the base platform 5 and configured to convey and release the filiform element F inside said industrial drum T forming a skein;
first actuation means, as a whole numbered with 7, coupled to the support framework 2 and configured to automatically move at least the pulling and dragging means 3, the returning and direction means 4 and the depositing means 6.

In accordance with the invention, the operational drum filler 1 comprises a loading station 8, defined in the support framework 2 where it is accessible to an operator P, distinct from the base platform 5 and configured to house, in this case, a series of industrial drums T (shown in number of three in figure 1, but for purely illustrative and exemplary purpose) that are still empty and subsequently to be filled with the filiform element F and operatively connected to second actuation means, overall indicated with 9, coupled to the support framework 2 and configured to automatically move, one after the other, the still empty industrial drums F towards the base platform 5.
In this case, therefore, the loading station 8 extends lengthwise inside the industrial plant so as to house a plurality of empty industrial drums T, forming an automatically movable accumulation station, as clearly shown in figure 1.
Moreover, the loading station 8 is structured in such a way as to feature a generic, generally composite, support surface 11 configured to receive the still empty industrial drums T and coplanar with an upper wall 5a of the base platform 5.
In a preferred but binding way, the loading station 8 comprises in this circumstance a single monolithic modular element 12, coplanar with the base platform 5 and provided with a plurality of leveling feet 13 projecting orthogonally from the lower surface 12a of the modular element 12 and adapted to rest on the support surface S.
It is understood, however, that in other embodiments of the operational drum filler of the invention, not illustrated in the following figures, the loading station may be of a composite type and comprise more than one modular element (of equal or different profile), arranged one side-by-side, adjacent, consecutive, and coplanar the other and mutually modular according to various spatial distributions, based on operative needs and, above all, the space available in the industrial environment in which the operational drum filler of the invention is installed.
Following the loading and advancement direction of the empty industrial drums T on the loading station 8, in particular on its support surface 11, the last portion 121 of the modular element 12 communicates with the base platform 5 to which it is attached.
More precisely and specifically, the loading station 8 comprises a connection module 14 positioned coplanarly between the base platform 5 and the last portion 121 of the modular element 12: in this case, the connection module 14 has, for example, the same rectangular profile but different dimensions (smaller only in length, while the width is the same to allow the regular transit of each industrial drum T) compared to those ones of the modular element 12, as it can be better seen from the enlargement of figure 2.
Preferably but not necessarily, the modular element 12 comprises a typical initial conveyor roller series 15, just as the connection module 14 comprises an intermediate conveyor roller 16 whose rollers are arranged in respective directions orthogonal to the directions of the rollers of the conveyor roller series 15.
It is understood even in this case that in other embodiments of the operational drum filler of the present invention, not depicted in the attached drawings, the at least one modular element could have dimensions and/or profile equal to the dimensions and/or profile of the connection module.
With reference to the second actuation means 9, they include any of the drive systems selected from the group consisting of pneumatic linear actuator, hydraulic linear actuator, electric motor and a mechanical transmission unit, motorized rollers (as in the example described and as clearly visible in figure 3), and the like. According to the preferred embodiment described herein of the invention, the operational drum filler 1 also includes an unloading station 10, defined in the support framework 2 and configured to house the industrial drum T arriving from the base platform 5 and complete with the skein of pre-twisted filiform element F formed by the depositing means 6, such as typically a mechanical device known as a flyer in the technical jargon of the sector.
Conveniently but not limited to, the unloading station 10 also includes a modular element of the same type as the modular element 12 (although smaller in size, in this specific case), arranged laterally and externally to the depositing means 6 and comprising a terminal conveyor roller series 17 accessible to the operator P.
It should be observed that the industrial drums T, complete inside with a skein-wrapped filiform element F and present on the base platform 5, are advantageously directed to the unloading station 10, progressively one after the other and in an automated manner by thrust means that are partially visible in figures 2 and 3 where they are generally indicated by the reference numeral 23; the thrust means 23 are supported by the support framework 2 and operate externally and laterally on the industrial drums T from a position above the base platform 5.
As far as the first actuation means 7 are concerned, they first of all comprise first movement means, collectively indicated by 18, cooperating with the depositing means 6 to rotate them around a main vertical axis Y and thus determine the winding of the filiform element F inside the industrial drum T.
Furthermore, the first actuation means 7 also comprise second movement means, collectively indicated by 19, cooperating with the depositing means 6 to make them slide upwards along a main vertical axis Y and thus maintain a constant distance between the skein being formed and the lower part of the mechanical member of the depositing means 6.
In addition, the first actuation means 7 also comprise third movement means, not visible, cooperating with the pulling and dragging means 3 (comprising in particular, the rotating inlet drum (or swivelling roller) 20 and the capstan 21) to direct the filiform element F towards the aforesaid depositing means 6, passing through the returning and direction means 4 (in this case including, by way of example, the series of wire straighteners 22).
By way of preferred but not limiting title, the first actuation means 7 also comprise fourth movement means, collectively indicated by 24, cooperating with the base platform 5 to rotate it around an auxiliary vertical axis Y' parallelly distinct and spaced part from the main vertical axis Y, such that the rotation of the base platform 5 is eccentric compared to the rotation of the depositing means 6, specifically of the flyer which preferably characterizes them.
Preferably, the first actuation means 7 also include fifth movement means, not shown in the attached figures, coupled to the support framework 2 and operatively connected to the base platform 5 to cause its vibration and promote the most regular possible stacking into coils of the filiform element F during the winding generated by the depositing means 6.
The subsequent figures 4-6 show a further possible embodiment of the invention in which the operational drum filler, now globally indicated by 50, differs from the operational drum filler 1 just described in relation to figures 1-3 due to the different spatial arrangement and the different composition or surface extension of the loading station 57, so configured due to the different availability of space in the industrial plant where the machinery of the invention is installed.
Arrows C in figures 4-6 indicate, particularly, the movement imparted to the industrial drum F in the operational drum filler 50.
It should also be noted that figures 4-6 show the flanged roller L arranged upstream of the support framework 51 and which, in use, supports the coil of filiform element F to be unwound into the operating drum 50 by the unwinding unit, which is not marked with a precise reference number.
Based on the description just provided, it is therefore clear that the operational drum filler for winding a filiform element into a skein inside an industrial drum (or container), object of the present invention, achieves the purposes and reaches the advantages mentioned above.
Upon implementation, changes could be made to the operational drum filler for winding a filiform element inside an industrial drum of the invention, consisting, for example, in a support framework of a different constructional design than those ones illustrated in the attached drawings.
In addition, further embodiments of the operational drum filler for winding a filiform element inside an industrial drum claimed herein may provide for a development of the loading station of the empty industrial drums different from that one described above and visible in the attached figures, which does not affect the advantage brought by the technical concept expressed by the invention, in particular by its independent claim.
It is finally clear that many other changes could be made to the operational drum filler for winding a filiform element inside an industrial drum concerned, falling within the scope of the appended claims, as it is equally apparent that in the practical implementation of the invention, the materials, shapes and sizes of the details shown may be of any kind, according to the needs.
Where the structural features and techniques mentioned in the following claims are followed by reference signs or numerals, such reference signs were introduced for the sole purpose of increasing the intelligibility of the claims themselves and therefore have no limiting effect on the interpretation of each element that is identified, purely by way of example, by those reference signs.

Claims

Operational drum filler (1; 50) for winding a filiform element (F) inside an industrial drum (T) comprising:
- a support framework (2; 51) suitable to rest on a support surface (S) and to be arranged downstream of an unwinding unit that unwinds a filiform element (F) from a reel wound around a flanged roller (L);

- pulling and dragging means (3) coupled to said support framework (2; 51) and configured to exert traction on said filiform element (F);

- returning and direction means (4), coupled to said support framework (2; 51) and arranged operatively downstream of said pulling and dragging means (3) from which they receive said filiform element (F);

- a base platform (5) coupled to a lower part (2a) of said support framework (2; 51) and configured to house in stable support an industrial drum (T) suitable to receive said filiform element (F) wrapped inside along a prefixed configuration;

- depositing means (6) arranged above said base platform (5) and configured to convey and release said filiform element (F) inside said industrial drum (T) forming a skein;

- first actuation means (7), coupled to said support framework (2; 51) and suitable to automatically move at least said pulling and dragging means (3), said returning and direction means (4) and said depositing means (6),
characterized in that it comprises a loading station (8; 57), defined in said support framework (2; 51) where it is accessible to an operator (P), distinct from said base platform (5) and configured to house one or more of said industrial drums (T) still empty and to be filled with said filiform element (F) and operatively connected to second actuation means (9) coupled to said support framework (2; 51) and suitable to automatically move one after the other said industrial drums (F) still empty towards said base platform (5).
Drum filler (1; 50) according to claim 1), characterized in that said loading station (8; 57) extends in length in such a way as to house a plurality of said empty industrial drums (T), forming an automatically movable accumulation station.
Drum filler (1; 50) according to claim 1) or 2), characterized in that said loading station (8; 57) is structured in such a way as to present a support surface (11) configured to receive one or more of said industrial drums (T) still empty and coplanar to an upper wall (5a) of said base platform (5).
Drum filler (1; 50) according to any of the preceding claims, characterized in that said loading station (8; 57) comprises one or more modular elements (12) coplanar to said base platform (5) and provided with a plurality of levelling feet (13) protruding from the lower surface (12a) of said modular elements (12) and suitable to rest on said support surface (S).
Drum filler according claim 4), characterized in that it comprises a series of said modular elements arranged adjacent to each other and coplanar to each other.
Drum filler (1; 50) according to claim 5), characterized in that, following the loading and advancement direction of said empty industrial drums (T) on said loading station (8; 57), the last portion (121) of said modular elements (12) communicates with said base platform (5) to which it is flanked.
Drum filler (1; 50) according to claim 5) or 6), characterized in that said loading station (8; 57) comprises a connection module (14) interposed in a coplanar manner between said base platform (5) and the last portion (121) of said modular elements (12) which have dimensions and/or profile equal each other or different from the dimensions and/or profile of said connection module (14).
Drum filler (1; 50) according to claim 4) or 5), characterized in that each of said modular elements (12) includes a conveyor roller series (15).
Drum filler (1; 50) according to any of the preceding claims, characterized in that said second actuation means (9) comprise any of the drive systems selected from the group consisting of pneumatic linear actuator, hydraulic linear actuator, electric motor and mechanical transmission unit, motorized rollers and the like.
Drum filler (1; 50) according to any of the preceding claims, characterized in that it comprises an unloading station (10), defined in said support framework (2; 51) and configured to house one by one said industrial drums (T) coming from said base platform (5) and complete with said skein of said filiform element (F) formed by said depositing means (6).
Drum filler (1; 50) according to claim 10), characterized in that said unloading station (10) comprises a terminal conveyor roller series (17) accessible to an operator (P).
Drum filler (1; 50) according to claim 10), characterized in that said first actuation means (7) comprise thrust means (23) coupled to said support framework (2; 51) and operatively connected to said base platform (5) to automatically move towards said unloading station (10), progressively one after the other, said industrial drums (T) filled with said wrapped filiform element (F).
Drum filler (1; 50) according to claim 12), characterized in that said first actuation means (7) comprise fifth movement means coupled to said support framework (2; 51) and operatively connected to said base platform (5) to determine its vibration.
Drum filler (1; 50) according to any of the preceding claims, characterized in that said first actuation means (7) include first movement means (18) cooperating with said depositing means (6) to rotate them around a main vertical axis (Y).
Drum filler (1; 50) according to any of the preceding claims, characterized in that said first actuation means (7) comprise second movement means (19) cooperating with said depositing means (6) to make them slide along a main vertical axis (Y).
Drum filler (1; 50) according to any of the preceding claims, characterized in that said first actuation means (7) comprise third movement means cooperating with said pulling and dragging means (3) to direct said filiform element (F) towards said depositing means (6).
Drum filler (1; 50) according to claim 14), characterized in that said first actuation means (7) comprise fourth movement means (24) cooperating with said base platform (5) to rotate it around an auxiliary vertical axis (Y') parallelly distinct and spaced apart from said main vertical axis (Y) in such a way that the rotation of said base platform (5) is eccentric compared to the rotation of said depositing means (6).