GB2233310A - Cable winding and packaging - Google Patents

Abstract

The cable winding apparatus includes a conveyor system (12) which moves empty cable formers (10) into position beneath a winding station (14) mounted on a support framework (22) above the conveyor (12). During winding of cable onto the former (10), a plate (36) is held against the top of the former (10) to prevent cable slipping over the top thereof. The cable is wound by means of a rotary/traverse cable guide (20) which has a rotating guide arm (24). As the guide arm (24) is raised and lowered to ensure an even winding, the plate (36) is kept in contact with the former (10) by a plate clamping mechanism (38,39, 45). The former (10) is a lightweight body comprising a pallet (40) and an integral frusto-conical body (42) onto which the cable is wound. A recess is provided in the base of the pallet (40) and frusto-conical body (42) to allow a number of such formers (10) to be nested when empty.

Description

1.

CAWZ WIMING AND PACMING The present invention relates to a method and apparatus for packaging of cables and in particular to such a method and apparatus in which the cable is wound onto a former.

One currently known and used system will now be described by way of example and with reference to figs. 1 and 2 of the accompanying drawings in which:

Figure 1 is a block diagram of a known cable packaging process; and Figure 2 schematically illustrates a number of stages of the process of Fig. 1.

In the known system, cable is wound onto a heavy frusto-conical steel former 100. At. the start of the cycle an errpty former is located between a third station 156 and a first station 152. A layer of corrugated paper or card is wrapped around the inclined surfaces of the former 100 and the former is then moved by a conveyor 120 in the direction A to the first station 152 where a flange plate 116 is attached to the top of the former.

The steel former 100 is then moved along path B on the conveyor system to a second station 154 where winding is effected by a rotating cable guide as shown in Fig. 2A. The cable guide comprises a heavy cowl 104 which is disposed over the former 100 and at the lower edge of which is a guide 1 102. Cable is fed into the top of the cowl 104 from a remote supply, and directed over the guide wheel 102 and onto the former 100. The rotating cowl 104 is driven by an electric motor 106 comected to it through a reduction gearing, &-d the cowl is raised and lowered during winding by a large hydraulic cylinder 106 so as to wind the cable onto the fonrer in layers - the required amount of cable has been wound onto the former, it is moved back to the first station 152, along path C,, where the body of wmaid cable 112 is banded with nylon straps. Th facilitate the banding operation, the flange plate 116 has a mmb--r of radial slots to allow the banding machine to feed the nylon banding down between the inclined surface of the former and the layer of corrugated card. The first station 152 generally has only a single banding machine and is provided with means for rotating the former 100 to successively align the radial slots in the flange plate 116 with the banding machine.

Following banding, the flange plate is removed and the former is transferred along path D to the third station 156 where it is inverted and lifted out of the banded cable pack 112, as shown in fig. 2B. The cable pack is then removed from underneath the raised former and transported along path E to a fourth station 158 whilst the former is lowered, re-inverted and returned in the direction A to start the next cycle. The cable pack then travels back along path F to the third station 156 where a flat pallet 114 is placed on top of it and the assembly of pallet and cable is inverted so that the cable sits m top of the pallet as shown in fig. 2C. The cable and pallet then returns along a path G to a station 158 where the cable is tested for electrical continuity and then along a path H to a packaging station 160 where both cable and pallet are wrapped in plastics material. The wrapped cable and pallet packs travel frern the packaging station 160 along path I to a final process station 162 where heat is applied to shrink the wrapping around the cable and pallet. The 1 shrink-wrapped cable packs are then ready for dispatch.

In practice there way be more than one former in circulation so that one former is being removed fram the wound cable pack and prepared for the next cycle whilst another former is being wound with cable.

When the cable is to be used, the wrapping and banding is removed. A folding umbrella-like device is used to retain the pack shape and prevent the pack collapsing or loops of wire beonning tangled, while the cable is being uncoiled from the pack. The device is inserted into the centre of the pack in a folded state and then opened up to engage the inside of the pack. A number of ribs carried by linkages from a central support, are moved outwardly frar this support to engage the inside of the cable pack and support the cable. A radial arm is mounted on a bearing at the top of the support device and carries an eye at its outer end through which the cable is passed. The arm rotates as the cable is drawn from the pack and prevents the wire that is being drawn off from catching and dislodging the top edge of the pack whilst the umbrella-like support device prevents the pack collapsing inwardly.

When the cable pack has been removed from the pallet, the empty f lat pallets my sinply be stacked, taking up little space whilst awaiting return to the packaging plant for re-use.

Y0hilst use of such a pack has the advantage over winding the cable onto a conventional flanged drum in that much less of the weight and bulk of the pack is taken up by packaging, it suffers from a number of disadvantages. The number of stages in the coiling and packing process increase the production time and costs. As can be seen from Fig. 1, the process involves a number of repeat visits to some processing stations ly, the packed cable may suffer from tangling or knotting once the banding has been removed to allow the cable to be unwound unless the custcuor has a suitable storage and dispensing apparatus to retain the pack shape during unwinding.

In accordance with the present invention there is provided a method of packaging electric cable rising the steps of winding the cable onto a frusto-conical former and securing the cable on the former so that it will not unwind during transportation.

The cable may be secured by merely tying in the ends of the cable. or by banding, or by wrapping in packaging material.

The use of such a method greatly sinplifies the packaging process as it allows the system to be based on a single conveyor line with no necessity for a former to travel back and forth during the process. The provision of a former also has the advantage that the customer need not provide a separate support device for holding the cable pack once the cable has been freed for removal, for wcanple, by removing the wrapping material.

Also in accordance with the present invention there is provided cable winding apparatus including means for transporting a former to a first process station where electric cable is wound onto the former and me= for ing the cable and former to a second process station where the cable on the former is secured on the former so that it will not unwind during transportation.

- 4 During winding of cable onto the former, which may be frusto-conical, a flange plate may be held against the reduced diameter end of the former. The plate, which acts to prevent the cable slipping off of the former during the winding operation, my be a free body attached to the former prior to the winding operation or it may be connected by means of a telescopic shaft to a rotating and linearly moving cable guide which winds the cable onto the former. The use of a telescopic shaft extendable along the axis of rotation of the cable guide and attached to the plate through a bearing allows the plate to rem-:dn stationary against the former as the cable guide rotates and rises and falls.

The apparatus way preferably include a conveyor system to move enpty formers from a supply into position relative to the first process station and, when winding is lete, to move the filled formers to the second station where the former and cable are wrapped. Clamping devices, such as pivoted catches actuated by hydraulic or pneumatic cylinders, may be provided to releasably hold the former in position at each process station.

The second station my comprise apparatus for wrapping the cable and the former onto which it is wound in wrapping material, for example paper, hessian or plastics material. The wrapping material may be a heat shrinkable plastics material, in which case, the wrapped cable/former packs may then be transported to a third station where they are heattreated to shrink wrap the plastics material around the cable and former. The leted packs way then be stored awaiting delivery.

Also in accordance with the present invention there is provided a -former for use in the transport and storage of cable rising a pallet with a frusto-conical body about which cable may be wound.

The former may have a frusto-conical recess in the base of the pallet corresponding in profile to the frusto-conical body. This would allow the nesting of such formers when -empty, in addition to reducing the overall weight of the former. The frusto-conical body my be a plastics moulding secured to the deck of a wooden pallet. Alternatively, the pallet and frusto-conical body my be formed as a unitary moulding of plastics material.

It is envisioned that such a lightweight stackable former mould be used in ination with the cable winding apparatus of the present invention, to provide a method of packing cables having fewer and simpler process steps than at present.

one particular preferred embodiment of the present invention will now be described by way of exarrple only, and with reference to figs. 3 to 8 of the accwpanying drawings, in which:

Figure 3 is a block diagram of the cable packing process of the present invention; Figure 4 shows the cable windIing apparatus of the present invention; Figure 5 is a side elevation of an empty cable former; Figure 6 shows the former of figure 5 wrapped with cable; Figure 7 is a plan view of the former of figure 5; and 4 Figure 8 shows a mrber of empty fonrers, as in figure 5, when stacked.

A preferred entodunent of the cable packing process of the present invention is illustrated in figures 3 and 4.

Empty cable formers 10 are taken fratt a supply 11 and carried along a path J on a conveyor system 12 to a winding station 14. At the winding station 14, each former 10 is cl in position relative to the winding apparatus by a number of hinged plates 16. Each hinged plate 16 is pivotable to engage and secure the base of the former 10 under the action of a hydraulic or pneumatic cylinder 18.

When cl in position, cable is uound onto the stationary former 10 by a rotating and traverse cable guide assembly 20.

The assembly 20, mounted on a support framework 22 over the conveyor system 12, corrprises a guide arm 24 mounted at the lower end of a centre shaft 32 and rotatable about the cl former 10. An electric motor 26 on a supporting yoke 27 is attached to the centre shaft 32 by bearing collars 25 at the upper and lower ends of the supporting yoke 27. Rotation of the centre shaft 32 and guide arm 24 is provided by the electric motor 26 through a belt drive 31 to the shaft. A traverse unit 28 rigidly attached to the supporting framework 22 raises and lowers the centre shaft 32, guide ann 24, motor 26 and supporting yoke 27 daring winding to provide an even spread of cable across the former 10. The traverse unit 28 is a "rolling-ring" unit of the type described in United Kin Patent No. 1602042 which provides axial displacement of the plain (unthreaded) rotating tubular centre shaft 32. The traverse unit 28 comprises a mmiber of ring shaped roller bodies at an angle to each other and to the centre shaft 32.

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When the required amount of cable has been wound onto the former 10, the plate 36 is then lifted from the top of the former 10 and the clamping plates 16 are pivoted to disengage from its base portion.

The former 10 with cable wound onto it is then moved along the conveyor system 12 on a path K. The cable, extending from the guide arm 24 to the former 10 is cut by a shearing device 37 mounted on the support framework 22. The severed end of the cable on the former 10 and the other end (arranged to protrude from the packed cable) are bared and the cable is then tested for electrical continuity at a test stage 35. If the test result is satisfactory the free ends of the cable are tucked into the body of the cable and the former with cable wound onto it, as shown in figure 6, is moved along path L on the conveyor system 12 to another station 43 where the former 10 and body of cable 44 are wrapped in plastics packing material. The wrapped cable/fonrer units are then transported along path M to a final process station 47 where they are heat treated to shrink the plastics material thereby retaining the cable on the former. As each former moves frcxt the winding station to the testing station the next former 10 is moved into position fram the supply 11 along path J and cl to undergo the 9 - 1 winding stage of the process at the winding station 14.

The fonrer 10 used in the above winding apparatus is preferably of the type sham in figures 5 to 8.

The former 10 omprises a flat wooden pallet 40 with a frusto-conical body 42 of plastics material onto which the cable is wound. The pallet 40 is of a size and construction to permit handling by standard fork-lift apparatus with a plywood deck 50 and wooden bearers 51.

In the upper surface of the pallet 40, there are a number of grooves 46 which extend tangentially from the base of the frusto-conical body 42 to the edge of the pallet 40. At the start of the winding operation, the cable stretches from the outside of the previously wound cable pack to the empty former where it will form the new cable pack. The cable lies in one of the grooves 46 in the upper surface of the pallet such that it is readily accessible for the electrical continuity test on letion of winding. The provision of the grooves 46 means that the weight of the cable pack 44 is not resting on the free end of the cable which may result in damage at the free end leading to failure of the continuity test. The grooves run tangentially frcm the base of the conical former at such an angle that the groove is aligned with the straight run of cable between the pack at the testing station and the pack at the winding station. This run of cable is cut after a few turns have been v m the new former at the winding station.

The deck of the pallet 40 has a circular opening and the underside of the frusto-conical body follows so that fonners 10a, 10b, 10c may be nested when empty, as shown in figure 8, without the frusto-conical body 42b of one former 10b, 1 4 k becaming jammed in the opening of the former 10a stacked on top of it.

Conveniently, the conical body and the grooved surface of the pallet my be formed as a unitary moulding fram plastics material and then secured to the plywood deck by nails, glue or other suitable means.

The cable winding apparatus described above.. together with its method of use, provides a more efficient and economic packing system than currently known and used methods. This occurs as a result of the reduction in the number of process sta", together with rationalisation of the process by ensuring that each pallet only visits each process station once during the winding operation.

The cable former of the present invention, either alone or in ination with the above mentioned method and apparatus, also provides a number of benefits. The shape of the packed cable is maintained when the external packaging (shrink-wrapping or banding) is removed, thereby reducing problem of knotting or tangling of cable and removing the necessity for custcmers to install specialised apparatus for storing the cable. Additionally, the former is a lightweight structure which way be easily and ctly stacked when empty, thereby reducing transport and storage costs.

4 CLAnE 1. A method of packaging electric cable omprising the steps of winding the cable onto a fnisto-conical former and securing the cable m the former so that it will not urmind during transportation.

2. A method according to claim 1, in which a flange plate is held against the smaller diameter end of the former during winding of cable onto the former.

3. A method according to claim 1 or claim 2, in which the foiTer renkLins stationary whilst cable is wound onto it.

4. A method according to claim 1, 2 or 3 in which the cable is secured on the former by wrapping the cable on the former in packaging material.

5. A method according to claim 4 in which the cable on the former is wrapped in plastics packaging material.

6. A method according to claim 5 in which the packaging material is a heat shrinkable material and including the further process step of heating the cable on the former to shrink the plastics packaging material wrapping the cable on the fonwr.

7. A method according to any preceding claim, including the step of testing the electrical continuity following winding of cable onto the former and prior to securing the cable to the former.

8. A method according to any preceding claim, in which a =ber of frustoconical formers are used, the formers being 4 f hollow and capable of nesting when effpty.

9. A method according to any preceding claim, in which the former is carried by a flat pallet which defines a flange extending from the bare of the former.

10. A method according to claim 9, in which the pallet has an opening in the underside thereof to permit nesting of a number of such pallets carrying formers when the said formers are elnpty- 11. Cable winding apparatus including means for transporting a former to a first process station where electric cable is wound onto the former and means for transporting the cable and former to a second process station where the cable on the former is secured on the former so that it will not unwind during transportation.

12. Apparatus according to claim 11, including a plate removably located against one end of the former, providing a flange extending therefrom during winding of cable onto the former.

13. Apparatus according to claim 12, in which cable is wound onto the former by a cable guide executing rotary and linear motion relative to the axis of the former.

14. Apparatus according to claim 13, in which the plate removably locatable against one end of the former is mounted on the cable guide and capable of rotary and linear motion in relation thereto.

15. Apparatus according to claim 12 or 13, including means for attaching the plate to the former prior to the first 1 1 4 1 process station and means for removing the plate prior to securing the cable m the former.

16. Apparatus according to claim 14, in which the means for mounting the plate m the cable guide is a telescopic shaft.

17. Apparatus according to claim 16, in which a bearing is provided between the plate and the telescopic shaft to permit rotation of the plate about the axis of the telescopic shaft.

18. Apparatus according to any of claims 11 to 17, in which the means for transporting a former is a conveyor assembly.

19. Apparatus according to any of claims 11 to 18, having means at each process station for clairping the former to prevent it moving during the process stage.

20. Apparatus according to claim 19, in which the clarrping mans comprise one or more plates movable to engage the former in response to fluid pressure.

21. Apparatus according to any of claims 11 to 20, in which the second process station has means for wrapping the cable on the former in packaging material to secure the cable on the former.

22. Apparatus according to claim 21, in which the second process station has means for wrapping the cable on the former in plastics packaging material.

23. Apparatus according to claim 22, in which the plastics packaging material is heat shrinkable material and couprising a third process station at which the cable and former wrapped in plastics packaging material are heat treated to shrink wrap 1 the plastics packaging material about the cable and former.

24. A former for use in the transport and storage of cable cmprising a pallet with a frusto-conical body about which cable may be wound.

25. A former according to claim 24, having a recess in the underside therof into which the frusto-conical body of a similar former nay be at least partially inserted when stacking empty formers.

26. A former according to claim 24 or claim 25 in which the frustoconical body is a plastics moulding and is attached to the decking of a wooden pallet.

27. A former according to any of claims 24 to 26 in which the frustoconical body is a plastics moulding and has an integral flange extending from the base thereof a cro ss the decking of a wooden pallet to which it is attached.

28. A former according to claim 24 or claim 25 in which the pallet and frusto-conical body are formed as a unitary moulding of plastics material.

29. Cable winding apparatus according to any of claim 11 to 23, including a former according to any of claim 24 to 28.

30. A method of packing electric cable according to any of claims 1 to 10, by means of apparatus according to claim 29.

31. Cable winding apparatus substantially as hereinbefore described with reference to figures 3 and 4 of the accmpanying drawings.

- is - X.

_e- -- 1 -1 ( 32. A former for use in the transport and storage of cable substantially as hereinbefore described with reference to figures 4 to 8 of the aconTipanying drawings.

33. A rethod of packing cable substantially as hereinbefore described with reference to figures 3 to 8 of the acccupeMing drawings - Published 1991 at 7he Patent Office. State House. 66171 High Holborn. London WC1R4TP. Further copies maybe obtained from The Patent Office. Sales Branch. St Mary Cray. Orpington. Kent BR5 3RD. Printed by Multiplex techniques lid. St Ma7rv Cray. Kent. Con. 1187