US3360016A - Rewinding process and apparatus - Google Patents

Rewinding process and apparatus Download PDF

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US3360016A
US3360016A US423721A US42372165A US3360016A US 3360016 A US3360016 A US 3360016A US 423721 A US423721 A US 423721A US 42372165 A US42372165 A US 42372165A US 3360016 A US3360016 A US 3360016A
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wire
bank
coil
coils
reel
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US423721A
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Fred K Coleman
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ETIWANDA STEEL PRODUCERS Inc
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ETIWANDA STEEL PRODUCERS Inc
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C47/00Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
    • B21C47/24Transferring coils to or from winding apparatus or to or from operative position therein; Preventing uncoiling during transfer
    • B21C47/245Devices for the replacement of full reels by empty reels or vice versa, without considerable loss of time

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  • ABSTRACT OF THE DISCLOSURE A continuous method for making wire coils wherein a number of individual coils are placed adjacent one another, an end of each coil is secured to the compatible end of the adjacent coil to make the individual coil continuous, the coils are uncoiled, the wire is reciprocally bent, precoiled, reciprocally guided for winding about a reel, and then is wound about the reel, the reel being rotated with constant torque.
  • This invention relates to a method and apparatus for rewinding loosely coiled wire rods (such as those used in reinforcing concrete) into longer continuous compactly wound coils.
  • the invention converts a dead cast mill coil into a longer tightly wound coil having improved shipping, storage, and pay-out characteristics.
  • the rods are customarily made in a rolling mill by passing steel rods at elevated temperatures through rollers which produce a welted rod having, for typical uses of the embodiment of the invention described herein, a diameter of A inch to /2 inch or more.
  • the hot wire is dead cast (loosely coiled) into coils roughly 3 feet in diameter and weighing about 200 pounds.
  • the dead cast mill coils have very poor pay-out characteristics and cannot be paid out circumferentially. Stated another way, if an attempt is made to unwind the mill coil circumferentially by rotating it about its axis, the coil snarls and smooth unwinding is impossible. -It may not be unwound on an A-frame, which is a material shortcoming because most manufacturing processes require such a method of unwinding. Thus, the mill coil must be paid out in a direction that generally corresponds to its axis by unwinding the coil convolution by convolution.
  • the dead cast mill coils are also undesirable in storage and shipping because the coil density is low, requiring excessive space.
  • the mill coils also tangle with one another easily. They are coated with a mill scale that must be removed prior to use. The length of individual mill coils is too short for efficient feeding into continuous processes because the spent coil must be too frequently replaced.
  • FIG. 7 is a variation in the design of one station and FIG. 15 shows the finished coil.
  • FIG. 1 is a diagram showing the stations in chronological sequence that are provided in the preferred embodiment of the invention.
  • FIG. 2 is a perspective view of the receiving station.
  • FIG. 3 is a perspective view showing the trimming station and movement from the receiving station thereto.
  • FIG. 4 is a perspective view of the welding station.
  • FIG. 5 is a side view of the flipping apparatus or starwheel which is included in the flipping station.
  • FIG. 6 is a top view of the star-wheel shown in FIG. 5.
  • FIG. 7 is a side view of a variation in the design of the star-wheel and includes vertically pivotal bank arms for vertical pay-out of the connected mill coils as shown.
  • FIG. 8 is a perspective view showing pay-out of the coil from the flipping station or star-wheel and impact descaling. Thus, it shows the descaling station and in addition shows a snarl actuated switch which stops the process in the event of snarling.
  • FIG. 9 is a side view of the straightening switch and pre-coiling station.
  • FIG. 10 is a top view of the straightening and pre-coiling stations :as shown in FIG. 9.
  • FIG. 11 is a side view of the guiding station taken in a direction corresponding to the input of the wire thereto.
  • FIG. 12 is a sectional side view taken on the line 12- 12 of FIG. 11.
  • FIG. 13 is a side view of the winding station.
  • FIG. 14 is a top view of the winding station as shown in FIG. 13.
  • FIG. 15 is a radial sectional view of a finished coil and shows the compact, level wound, and generally rectangular radial cross section of the finished coil.
  • the process of the present invention includes placing a plurality of individual mill coils adjacent to one another with their ends hanging symmetrically beneath the coil to form a first bank of coils, securing one end of one coil to the compatible end of the adjacent coil, providing a second bank of individual coils and securing one end of one coil in the second bank to the compatible end of the adjacent coil, and securing the end of the first placed individual coil of the first bank to the compatible end of the last placed coil in the second bank, providing a third bank in a manner similar to the provision of the first and second banks, continuously uncoiling the wire from the first bank, applying a tensile force to the wire, reciprocally bending the wire, winding the wire about a precoiler, reciprocally guiding the wire into a take-up reel and continuously winding the wire about the take-up reel to form a finished coil.
  • the process may be conveniently carried out with the aid of the apparatus appearing in FIGS. 1-6 and 8-14.
  • the apparatus defines the various stations designated in FIG. 1.
  • the receiving station (FIG. 2) consists of a frame 20 and a platform 21, mounted for convenient movement on wheels 22 and rails 23. Individual loosely wound mill coils 24 are placed on frame 20 in any convenient manner such as by a fork lift truck. Frame 20 is then moved into position in close proximity of the trimming station.
  • the mill coils are then moved from the receiving station by means of monorail hoist 25 as shown by arrow A to the trimming station (FIG. 3).
  • the irregular ends of the mill coils 24 are sheared by hydraulic shear 26 so that they hang symmetrically below mill coil 24 which is apparent with reference to mill coil ends 24a and 24b (FIG. 3).
  • the mill coil 24 is moved by monorail hoist 25 as shown by arrow B and placed adjacent other mill coils to form a first bank of coils referred to generally by reference number 27.
  • the mill coils 24 are placed in bank 27 so that adjacent ends of adjacent coils are compatible.
  • Compatibility requires that adjacent ends of adjacent coils intersect (as opposed to hanging parallel) so that they may be butt welded to form a continuous wire made up of a number of mill coils. This is best seen with reference to bank 27 of FIG. 3. There mill coil ends 24b(1) and 24a(2) are compatible and adjacent mill coils 24(1) and 24(2) must be oriented in bank 27 to achieve this compatibility.
  • bank 27 is moved to the welding station (FIG. 4). There compatible ends 24a of one mill coil and 24b of the adjacent coil are butt welded together. Flash butt welder 28 is provided for that purpose. End 24b(n) is butt welded to the compatible end 24a(1) of the last placed mill coil on bank 27b so that uncoiling of bank 27a leads continuously to the uncoiling of bank 27b. The uncoiling appears best in FIG. 8. If desired the welds may be color-marked at this point for manual or photoelectric rejection in subsequent manufacturing processes inwhich use of weld-containing sections is undesirable.
  • the flipping station comprises a star-wheel referred to generally as 29 andbest viewed in FIGS. 5 and 6.
  • the star-wheel includes a' base 30, a substantially vertical member 31, and bank arms 32 radially secured to sleeve 33.
  • Member 31 is preferably tilted from the vertical so that the bank from which uncoiling is accomplished is inclined upwardly in the direction of the uncoiling.
  • Sleeve 33 is mounted for rotational movement about substantially vertical member 31 and includes pin 34 mounted for rotational movement in sleeve 33 (but not slidable therein) and in bearing socket 35 of member 31.
  • Sleeve sprocket 36 is fixed to the lower extremity of sleeve 33.
  • Motor 37 is mounted to member 31 by means ofmounting brackets 38.
  • Chain 39 provides a linkage from the motor sprocket 40 to sleeve sprocket 36 so that rotation of motor sprocket 49 provides a rotational movement of sleeve sprocket 36, sleeve 33 and bank arms 32.
  • Triangular gnssets 41, 4'2, and 43 are rigidly secured tosleeve 33 and bank arms 32 to provide a reinforced rigid joint.
  • Intermediate gussets 42 are three in number and provide a web portion between the bank arms 32 as best seen in FIG. 6.
  • Upper gusset 41 is secured to the upper surface of bank arms 32 and positioned so that its corners extend in the same direction as arms 32 which also can be best seen in FIG; 6.
  • Lower gusset 43 is larger than upper gusset 41 and is positioned out of phase with respect to upper gusset 41.
  • lower gusset 43 is oriented so that its edges 43a, b, and c are perpendicular to the axis of bank arms 32a, b, and respectively.
  • the edges 43a, b, and c provide a surface which aligns banks 27 as the inner mill roll of the bank abuts the edges.
  • Drop arm 44 is pivotally mounted to the underside of bank arm 32 by means of bracket 45 and pin 46. It is suspended on chain 47 which is secured at one end to bank arm 32. The position of drop arm 44 may be changed by lengthening or shortening chain 47 from the dropped position shown in FIG. to a retracted position (not shown) wherein drop arm 44 is parallel and adjacent to bank arm 32.
  • overarm 48 is pivotally connected to pin 34 by means of bracket 49 and pin 50. Since pin 34 is rotatable about its axis independent of the rotation of sleeve 33, overarm 48 may be positioned over either bank arm 32a (as shown), 32b, or 320 (not shown). Thus, it may be positioned over Whichever bank is being paid out for the purpose of controlling pay-out of the coil convolutions as shown in FIG. 5. There overarm 48 rests against the upper surface of bank arm 32 to control the pay-out of coil 24. Drop arm 44 is shown in a dropped position to assist in controlling the pay-out as may be readily seen.
  • overarm 48 is pivoted about the axis of pin 34 and associated with another bank arm (from which uncoiling is progressing) and drop arm .-4 is retracted to a position adjacent bank arm 32.
  • the descaling station consists merely of a hard rough surface 51 (roughly surfaced concrete, for example), which is abrasive. As the coil convolutions are pulled in the direction of arrow C and drop onto the surface 51, the impact and abrasion against surface 51 removes a significant portion of the mill scale.
  • Snarl switch assembly 52 comprises hoop 53 through which the wire is threaded as shown in FIG. 8.
  • Hoop 53 is pivotally mounted to base 54.
  • Conduit 55 is also mounted to base 54 and conducts leads 56 from a switch (not shown) mounted on base 54 toward the precoiling station (where they are connected to the precoiler drive motor circuit so that opening the switch stops the motor).
  • Hoop 53 is pivoted about its vertical axis whenever a snarl prevents passage of the wire W therethrough. The pivoting opens the switch and stops the precoiler motor. Thus, any snarl automatically stops the rewinding process.
  • the wire W next passes through the straightening and precoiling stations which appear in FIGS. 9 and 10.
  • the straightening station includes bell mouth entry cone assembly 57, straightener 58 and base 59.
  • Entry cone 57 includes entry rollers 60 mounted for rotational movement on four axes respectively which lie in a common plane perpendicular to the direction of travel of the wire W and define a square.
  • Rollers 60a and 60b are mounted to brackets 61a and 6112 respectively.
  • Rollers 60c and 60d are mounted to bracket 61c and 61d respectively.
  • Brackets 61a-d are mounted to brackets 62a and 6212 which is in turn mounted to base 59.
  • Bracket 62b contains an input aperture 64 which has a diameter approximately equal to the diameter of the entry rollers 60 and exposes approximately one-half the diameter of each. Thus, an entry cone is provided for the wire W. Entry rollers 60 are spaced such that they define a square passage having dimensions slightly less than the diameter of wire W. An output aperture sleeve 63 is provided in bracket 62a through which wire W exits. A drag mechanism (not shown) may be provided to inhibit rotation of rollers '60 to produce tension in wire W between entry cone assembly 57 and straightener 58.
  • Straightener 58 includes frame 65, an upper bank of rollers 66a, 12, and c and a lower bank of rollers 67a-d
  • Therollers 66 and 67 contain a concave peripheral surface which is best seen in FIG. 10 at 68.
  • Rollers 67 are rotatably mounted to frame on shafts 69.
  • Upper bank 66 is rotatably mounted to mounting plates 70.
  • Rollers 66 are vertically adjustable by means of rotation of adjusting screws 7 1.
  • Mounting plates 70 are connected to a common frame member (not shown) which may be raised or lowered by means of lever 72 and. linkage 73 to respectively disengage and engage wire W.
  • the rollers 65 and 66 are horizontally aligned as best seen in FIG. 10. They are vertically staggered as best seen in FIG.
  • the straightener 58 cold works the steel, removes the remaining mill scale and eliminates the bending-moment resiliency induced by the first coiling as'the wire is dead cast from the rolling mill. The cold working also increases the yield point.
  • Wire W is drawn through straightener 58 by means of precoiler 76 which is mounted to base 59 and forms the precoiling station referred to generally at 74.
  • Precoiler station 74 includes a precoiling motor (not shown) which drives shaft 75 and precoiler 76.
  • precoiler 76 is concave at its circumference which can be best seen at 77 in FIG. 10. It is of sufiicient width or thickness 77 to accommodate two diameters of wire.
  • the precoiling motor is driven at an adjustable speed which remains constant regardless of load. Wire W is wound around precoiler 76 for one convolution and paid out in the direction of arrow D.
  • wire W upon its entry to precoiler 76, wire W is under tension. Passage about precoiler 76 induces a bending moment resiliency, and the diameter of precoiler 76 is chosen so that this bending moment resiliency generally tends to hold the wire in a curvature approximately equal to the inner diameter of the finished coil.
  • Precoiler 76 is, of course, aligned with straightener 58 and entry cone assembly 57.
  • wire W is fed through the guiding station (FIGS. 11 and 12). It passes first between entry rollers 78 and then between gripping rollers 79. Both rollers 78 and 79 are mounted for rotation about the respective entry roller shafts 80 and gripping roller shafts 81. Roller shafts 80 and 81 are mounted in a generally vertical plane but are tilted toward the direction of entry of wire W as best seen in FIG. 12. Gripping roller shafts 81 are mounted at each end to brackets 82 which are in turn rigidly secured to entry roller shafts 80. Gripping roller shafts 81 therefore pivot about the axis of entry roller shaft 80 on brackets 82 as entry roller shafts 80 are pivoted.
  • Entry roller shafts 80 extend through and are journaled in upper plate 83 and lower plate 84 at 85 and 86 respectively.
  • Upper and lower plate 83 and 84 are mounted for reciprocal movement on bars 87 and 88 respectively. This is accomplished through the use of side plates 89 which are rigidly mounted to upper and lower plates 83 and 84 and contain integral mounting brackets 90 and 91 fixed to sleeves 92 and 93 respectively which are slidable along bars 87 and 88 respectively.
  • the guide and gripping roller assembly is mounted for reciprocal movement on bars 87 and 88 in the direction of arrows E as shown in FIG. 11.
  • Bars 87 and 88 are mounted in mounting brackets 94 and 95.
  • Mounting bracket 94 is reinforced against tilting by web 96.
  • the mounting brackets 94 and 95 are rigidly secured to frame 97.
  • Canvas bellows 98 are provided on a coil spring skeleton 99 to serve as a dust cover in the area of bars 87 and 88 not covered by sleeves 92 and 93.
  • Studs 100 are fixed to upper plate 83.
  • Bolts 101 extend through studs 100 and are spring loaded against nut 102.
  • the ends of bolts 101 opposite nut 102 are pivotally connected to arms 103.
  • Arms 103 are rigidly connected to entry roller shafts 80.
  • the spring mounting of bolts 101 also holds gripping rollers 79 resiliently against wire W and, together with stud 100, provides a method for adjusting the spacing between gripping rollers 79 to accommoate various wire diameters.
  • Guide roller brackets 104 and 105 are mounted on upper plate 83 and lower plate 84 respectively.
  • Guide rollers 106 and 107 are mounted for rotational movement on shafts 108 and 109 respectively which in turn are mounted to brackets 104 and 105.
  • Guide rollers 106 and 107 serve to limit the vertical traverse of Wire W to somewhat less than the length of entry and gripping rollers 78 and 79.
  • Pawl housing 110 is mounted to the lower side of lower plate 84 and envelops worm gear shaft 111.
  • Pawl 112 is removably mounted in pawl housing 110 and engages the track of worm gear shaft 111 which is mounted for rotational movement in mounting bracket 94 and bearing 113.
  • Worm gear shaft sprockets 114 is linked with gear reducer sprocket 115 by means of chain 116.
  • Gear reducer 117 is mounted to frame 97 and power is supplied to sprocket 118 from a power source not shown.
  • the gripping and roller assembly thereby reciprocates on bars 87 and 88 as shown by arrow B in FIG. 11.
  • the traverse of pawl 112 and as a result gripping rollers 79, is equal to the width of the take-up reel 119 minus the diameter of the wire.
  • the speed of rotation of worm gear shaft 111 is coordinated with the speed of rotation of the take-up reel through gear reducer 117, to insure a level wound finished coil.
  • gear reducer 117 adjusts the speed of worm gear 111 to compensate for a change in the wire diameter due to the winding of various diameter wires from time to time.
  • wire W proceeds to the winding station (FIGS. 13 and 14) where it is wound on take-up reel 119a.
  • the winding station includes frame 120 to which is mounted turntable motor 121 and take-up reel motor 122.
  • Turntable shaft 123 is journaled on frame 120 in bearings 124.
  • a turntable sprocket 125 is rigidly secured to one end of turntable shaft 123 and linked by chain 126 to sprocket 127 of turntable motor 121.
  • Turntable arms 128a and 128b extend radially from turntable shaft 123 and are rigidly secured thereto.
  • turntable arms 128 contain sleeves 129. They are rigidly secured to arms 128 having their axes parallel to the axis of turntable shaft 123. Reel shafts are mounted in sleeves 129 for rotation therein and extend beyond one end of sleeves 129 terminating at a threaded engagement with wing nuts 131. The opposite end of shaft 130 terminates at joint 132.
  • Take-up reel motor sprocket 133 is linked by chain 134 to reel drive sprocket 135.
  • Reel drive shaft 136 extends rigidly from reel drive sprocket and is journaled in bearing 137 and terminates at universal joint 132, at that point being fixed to reel shaft 130a.
  • Joint 132 is capable of quick assembly and disassembly to connect drive shaft 136 to reel shaft 130 and to sever the connection respectively by hydraulically shifting shaft 136 along its axis. When shifted to abut reel shaft 130 as shown in FIG. 14 joint 132 is engaged and the rotation of shaft 136 rotates reel shaft 130. The joint is hydraulically disengaged when reel 119a is removed from the take-up position and an empty reel takes its place.
  • Lock arm 138 is pivotally connected to lock arm bracket 1380 which is mounted to frame 120.
  • Look arm 138 is two-sided as may be seen by reference to side 138a and 138b in FIG. 14. Each side is arcuately notched to a depth equal to the outside radius of sleeve 129. It therefore accommodates sleeve 129 and locks turntable arms 128 in the position shown in FIG. 13 and prevents sweeping movement in the direction of arrow F. Thus, arms 128 and reel 119a are locked in a take-up position with shaft 130a aligned with reel drive shaft 136. The positions are simultaneously interchangeable by disengaging lock arm 138 and sweeping turntable arms 128 one hundred eighty degrees. Lock arm 138 is engaged and disengaged with sleeve 129 by means of hydraulically operated jack 139 which is fixed at one end to guiding station frame 97 and at the other end to lock arm 138.
  • Take-up reels 119 are mounted for rotation on reel shafts 130.
  • Reels 119 consist of spool 140, permanent flange 141 and removable flange 142.
  • Spool 140 is keyed to reel shaft 130.
  • Both flanges 141 and 142 as well as spool 140 contain slots 144 which are radially positioned and spaced one hundred twenty degrees from one another.
  • Flange 142 is removable by removing wing nut 131.
  • the winding station is aligned with the guiding station so that a line passing through a plane equidistant from reel flanges 141 and 142 perpendicularly bisects the tra verse of entry and gripping rollers 78 and 79.
  • bank arm 232 contains joint 233 which is pivotable about pin 234 in the direction of arrow G.
  • bank arm 232 has two positions with respect to vertical arm 231. One position is perpendicular to arm 231 for placement of mill coils thereon and the other position is parallel to arm 231 for pay-out.
  • Bank arm 232 is pivoted about pin 234 by means of hydraulic linkage 235 which is pivotally connected at one end to arm 232 and at the other end to vertical member 231 as shown in FIG. 7.
  • hydraulic linkage 235 which is pivotally connected at one end to arm 232 and at the other end to vertical member 231 as shown in FIG. 7.
  • Mill coils are received and passed through the trimming, welding, flipping, descaling, straightening, precoiling, and guiding stations where wire W is handled and processed as previously described.
  • the end is then fixed to spool 140 and take-up drive motor applies a constant torque to reel drive sprocket 135 to turn reel 119 and Wind wire W thereon.
  • the take-up reel speed is a function of the precoiler speed and the outside diameter of the finished coil at any given moment.
  • the guiding station operates at a speed which is directly proportional to the speed of take-up reel 119a.
  • the coil is steel-strapped by inserting steel straps 143 into slots 144 and circumscribing the radial section of the finished coil 145.
  • Turntable arms 128 are then actuated and the position of reel 11% is interchanged with reel 11%.
  • Reel 119a is thus swept into an unloading position and reel 119/5 is swept into a take-up position. Winding is begun on reel. 11% as previously done on reel 119a.
  • wing nut 131a is removed along with flange 142 to expose finished coil 145.
  • Coil 145 is removed from spool 140 and the process has produced one unit.
  • the finished coil which appears in FIG. 15 is tightly and level wound as may be seen with reference to the radial cross-section. It is compact, which is desirable for storage and transport, and free of mill scale. After the retaining straps are cut it may be smoothly paid out by rotation about its axis (on an A-frame for example). It is therefore, unlike the dead cast mill coil, a suitable raw material for subsequent automatic or manual manufacturing processes in various industries.
  • a continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another, securing an end of one of said individual coils to the compatible end of the adjacent coil thereby making said individual coils continuous, uncoiling said continuous individual coils, reciprocally bending said wire, passing said wire under tension about a precoiler and continuously removing said wire therefrom, reciprocally guiding said wire for level winding about a reel in a take-up position, rotating said reel with constant torque and winding said wire about said reel to form said coil.
  • a continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another to form a first bank of coils having a longitudinal axis extending radially from a substantial vertical axis, sweeping said first bank arcuately about said substantially vertical axis, securing an end of one of said coils to the compatible end of the adjacent coil, placing a plurality of said individual coils adjacent one another to form a second bank of coils having a longitudinal axis extending radially from said vertical axis, sweeping said banks arcuately about said substantially vertical axis, securing one end of the coil in said first bank nearest said vertical axis to the compatible end of the coil in said second bank farthest from said vertical axis, securing an end of one of said coils in said second bank to the compatible end of the adjacent coil, again placing a plurality of said individual coils adjacent one another to form a third bank, securing one end of the coil in said second bank nearest said vertical axi
  • the method of claim 2 further characterized by securing said wire coil about a plurality of radial crosssections equally spaced on the circumference thereof, severing said wire, removing said reel with said secured coil thereon from said take-up position and simultaneously replacing said reel, removing a flange of said reel and removing said secured coil therefrom.
  • a continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another with the ends of said coils hanging symmetrically beneath said coils and crossing the adjacent end of the adjacent coil to form a first bank of coils having a longitudinal axis extending radially from a substantially vertical axis, sweeping said first bank arcuately about said substantially vertical axis, abutting and securing an end of one of said coils to the adjacent compatible end of the adjacent coil, placing a plurality of said individual coils adjacent one another with the ends of said coils hanging symmetrically beneath said coils and crossing the adjacent end of the adjacent coil to form a second bank of coils having a longitudinal axis extending radially from said substantially vertical axis, sweeping said banks arcuately about said substantially vertical axis, abutting and securing one end of the coil in said first bank nearest said substantially vertical axis to the compatible end of the coil in said second bank farthest from said vertical axis,
  • Apparatus for making wire coils from shorter individual coils which comprises, in combination: a starwheel having a substantially vertical elongate member mounted for rotation about its axis and three elongate arms equally spaced and radially mounted thereto, an entry cone roller assembly including four rollers mounted with their axes in a vertical plane and defining a square, said rollers forming a square passage having a dimension substantially equal to the diameter of said wire, a straightener having an upper bank of rollers and a lower bank, said rollers being circumferentially concave and horizontally aligned but vertically positioned with said upper bank intermeshed with said lower bank, a precoiler having a circumferentially concave surface and means for driving said precoiler at a constant speed, a guiding mechanism having a pair of substantially vertically positioned entry rollers and gripping rollers, said entry rollers being spaced a distance substantially equal to the diameter of said wire, and said gripping roller mounted for arcuate movement about said entry rollers and means

Description

Dec. 26, 1967 F. K. COLEMAN 0, 1
REWINDING PROCESS .AND APPARATUS Filed Jan. 6, 1965 s Sheets-Sheet 1 WELDING Fuppmg PRELIMINARY STRIAIGHTENING PRECOILING STATION STATION gig? G sumo" STATION (FIG 4) (FIG sae) (FIG 8) (FIG 9) (FIG w) 4 Y T MING GUIDING s "non STATION (Flea) (FIG llalz) Q II E; II
RECEIVING wmome STATION STATION (FIG 2 (FIG laal4) INVENTOR. FRED K. COLEMAN Dec. 26; 1967 F. K. COLEMAN REWINDING PROCESS AND APPARATUS Filed Jan. 6, 1965 5 Sheets-Sheet 2 INVENTOR FRED K. COLEMAN ATTORNEYS Dec. 26, 1967 F. K. COLEMAN 3,360,016
REWINDING PROCESS AND APPARATUS I Filed Jan. 6, 1965 5 Sheets-Sheet :5
T 71 7s es INVENTOR.
FRED K. COLEMAN ATTORNEYS Dec. 26, 1967 COLEMAN A I 3,360,016
REWINDING PROCESS AND APPARATUS Filed Jan. 6, 1965 5 Sheets-Sheet 4 87 :VI/IZ E H l2 V llLl -W 9s ns 94 n 99 -78 III-"NH:
n ,-J| H4 H g H II -97 II A H {I |I6--J: V :I I II? I us {I INVENTOR.
FRED K. COLEMAN BY ATTORNEYS Dec. 26, 1967 F. K. COLEMAN REWINDING PROCESS AND APPARATUS Filed Jan. 6, 1965 5 Sheets-Sheet 5 INVENTOR.
- FRED K. COLEMAN BY My M, 71/
ATTORNEYS United States Patent 3,360,016 REWINDING PROCESS AND APPARATUS Fred K. Coleman, Los Alamitos, Calif., assignor to Etiwanda Steel Producers, Inc., Etiwanda, Califi, a corporation of California Filed Jan. 6, 1965, Ser. No. 423,721 9 Claims. (Cl. 1401) ABSTRACT OF THE DISCLOSURE A continuous method for making wire coils wherein a number of individual coils are placed adjacent one another, an end of each coil is secured to the compatible end of the adjacent coil to make the individual coil continuous, the coils are uncoiled, the wire is reciprocally bent, precoiled, reciprocally guided for winding about a reel, and then is wound about the reel, the reel being rotated with constant torque.
This invention relates to a method and apparatus for rewinding loosely coiled wire rods (such as those used in reinforcing concrete) into longer continuous compactly wound coils. The invention converts a dead cast mill coil into a longer tightly wound coil having improved shipping, storage, and pay-out characteristics.
In the art of manufacturing reinforcing rods or wire for concrete structures, the rods are customarily made in a rolling mill by passing steel rods at elevated temperatures through rollers which produce a welted rod having, for typical uses of the embodiment of the invention described herein, a diameter of A inch to /2 inch or more. Upon exit from the rolling mill, the hot wire is dead cast (loosely coiled) into coils roughly 3 feet in diameter and weighing about 200 pounds.
The dead cast mill coils have very poor pay-out characteristics and cannot be paid out circumferentially. Stated another way, if an attempt is made to unwind the mill coil circumferentially by rotating it about its axis, the coil snarls and smooth unwinding is impossible. -It may not be unwound on an A-frame, which is a material shortcoming because most manufacturing processes require such a method of unwinding. Thus, the mill coil must be paid out in a direction that generally corresponds to its axis by unwinding the coil convolution by convolution.
The dead cast mill coils are also undesirable in storage and shipping because the coil density is low, requiring excessive space. The mill coils also tangle with one another easily. They are coated with a mill scale that must be removed prior to use. The length of individual mill coils is too short for efficient feeding into continuous processes because the spent coil must be too frequently replaced.
Accordingly, the invention has for its objects:
To provide a level and tightly wound coil that may be uncoiled by rotation about its axis smoothly without snarlmg. i
To provide a compactly wound coil having a generally rectangular radial cross section.
To provide a continuous method for connecting loosely wound mill coils, uncoiling the mill coils, cold working the wire, and rewinding it into a tightly and level wound finished coil.
To provide a method for rewinding mill coils which in corporates a cold working of the wire to increase its strength and remove mill scale therefrom.
To provide a novel method and apparatus for continuously forming a plurality of banks of mill coils, connecting adjacent mill coils and adjacent banks, and continuously uncoiling connected coils from a bank.
To provide a continuous method for rewinding uncoiled wire wherein the take-up reel is drawn with constant torque and the wire is fed into the take-up reel at a constant speed to insure a uniformly tightly wound finished coil.
To provide a method for efiiciently removing a finished coil from the take-up position, removing the finished coil from the take-up reel, and placing an unfilled reel in the take-up position.
Each of the objects is fulfilled in the specific embodiment which appears in FIGS. 1-6 and 8-14. FIG. 7 is a variation in the design of one station and FIG. 15 shows the finished coil. With reference to the drawings:
FIG. 1 is a diagram showing the stations in chronological sequence that are provided in the preferred embodiment of the invention.
FIG. 2 is a perspective view of the receiving station.
FIG. 3 is a perspective view showing the trimming station and movement from the receiving station thereto.
FIG. 4 is a perspective view of the welding station.
FIG. 5 is a side view of the flipping apparatus or starwheel which is included in the flipping station.
FIG. 6 is a top view of the star-wheel shown in FIG. 5.
FIG. 7 is a side view of a variation in the design of the star-wheel and includes vertically pivotal bank arms for vertical pay-out of the connected mill coils as shown.
FIG. 8 is a perspective view showing pay-out of the coil from the flipping station or star-wheel and impact descaling. Thus, it shows the descaling station and in addition shows a snarl actuated switch which stops the process in the event of snarling.
FIG. 9 is a side view of the straightening switch and pre-coiling station.
FIG. 10 is a top view of the straightening and pre-coiling stations :as shown in FIG. 9.
FIG. 11 is a side view of the guiding station taken in a direction corresponding to the input of the wire thereto.
FIG. 12 is a sectional side view taken on the line 12- 12 of FIG. 11.
FIG. 13 is a side view of the winding station.
FIG. 14 is a top view of the winding station as shown in FIG. 13.
FIG. 15 is a radial sectional view of a finished coil and shows the compact, level wound, and generally rectangular radial cross section of the finished coil.
The process of the present invention includes placing a plurality of individual mill coils adjacent to one another with their ends hanging symmetrically beneath the coil to form a first bank of coils, securing one end of one coil to the compatible end of the adjacent coil, providing a second bank of individual coils and securing one end of one coil in the second bank to the compatible end of the adjacent coil, and securing the end of the first placed individual coil of the first bank to the compatible end of the last placed coil in the second bank, providing a third bank in a manner similar to the provision of the first and second banks, continuously uncoiling the wire from the first bank, applying a tensile force to the wire, reciprocally bending the wire, winding the wire about a precoiler, reciprocally guiding the wire into a take-up reel and continuously winding the wire about the take-up reel to form a finished coil.
The process may be conveniently carried out with the aid of the apparatus appearing in FIGS. 1-6 and 8-14. The apparatus defines the various stations designated in FIG. 1.
The receiving station (FIG. 2) consists of a frame 20 and a platform 21, mounted for convenient movement on wheels 22 and rails 23. Individual loosely wound mill coils 24 are placed on frame 20 in any convenient manner such as by a fork lift truck. Frame 20 is then moved into position in close proximity of the trimming station.
The mill coils are then moved from the receiving station by means of monorail hoist 25 as shown by arrow A to the trimming station (FIG. 3). The irregular ends of the mill coils 24 are sheared by hydraulic shear 26 so that they hang symmetrically below mill coil 24 which is apparent with reference to mill coil ends 24a and 24b (FIG. 3). After shearing or trimming the mill coil 24 is moved by monorail hoist 25 as shown by arrow B and placed adjacent other mill coils to form a first bank of coils referred to generally by reference number 27. The mill coils 24 are placed in bank 27 so that adjacent ends of adjacent coils are compatible. Compatibility requires that adjacent ends of adjacent coils intersect (as opposed to hanging parallel) so that they may be butt welded to form a continuous wire made up of a number of mill coils. This is best seen with reference to bank 27 of FIG. 3. There mill coil ends 24b(1) and 24a(2) are compatible and adjacent mill coils 24(1) and 24(2) must be oriented in bank 27 to achieve this compatibility.
From the trimming station bank 27 is moved to the welding station (FIG. 4). There compatible ends 24a of one mill coil and 24b of the adjacent coil are butt welded together. Flash butt welder 28 is provided for that purpose. End 24b(n) is butt welded to the compatible end 24a(1) of the last placed mill coil on bank 27b so that uncoiling of bank 27a leads continuously to the uncoiling of bank 27b. The uncoiling appears best in FIG. 8. If desired the welds may be color-marked at this point for manual or photoelectric rejection in subsequent manufacturing processes inwhich use of weld-containing sections is undesirable.
The flipping station comprises a star-wheel referred to generally as 29 andbest viewed in FIGS. 5 and 6. The star-wheel includes a' base 30, a substantially vertical member 31, and bank arms 32 radially secured to sleeve 33. Member 31 is preferably tilted from the vertical so that the bank from which uncoiling is accomplished is inclined upwardly in the direction of the uncoiling. Sleeve 33 is mounted for rotational movement about substantially vertical member 31 and includes pin 34 mounted for rotational movement in sleeve 33 (but not slidable therein) and in bearing socket 35 of member 31. Sleeve sprocket 36 is fixed to the lower extremity of sleeve 33. Motor 37 is mounted to member 31 by means ofmounting brackets 38. Chain 39 provides a linkage from the motor sprocket 40 to sleeve sprocket 36 so that rotation of motor sprocket 49 provides a rotational movement of sleeve sprocket 36, sleeve 33 and bank arms 32. Triangular gnssets 41, 4'2, and 43 are rigidly secured tosleeve 33 and bank arms 32 to provide a reinforced rigid joint. Intermediate gussets 42 are three in number and provide a web portion between the bank arms 32 as best seen in FIG. 6. Upper gusset 41 is secured to the upper surface of bank arms 32 and positioned so that its corners extend in the same direction as arms 32 which also can be best seen in FIG; 6. Lower gusset 43 is larger than upper gusset 41 and is positioned out of phase with respect to upper gusset 41. Thus, lower gusset 43 is oriented so that its edges 43a, b, and c are perpendicular to the axis of bank arms 32a, b, and respectively. The edges 43a, b, and c provide a surface which aligns banks 27 as the inner mill roll of the bank abuts the edges.
Drop arm 44 is pivotally mounted to the underside of bank arm 32 by means of bracket 45 and pin 46. It is suspended on chain 47 which is secured at one end to bank arm 32. The position of drop arm 44 may be changed by lengthening or shortening chain 47 from the dropped position shown in FIG. to a retracted position (not shown) wherein drop arm 44 is parallel and adjacent to bank arm 32.
An overarm 48 is pivotally connected to pin 34 by means of bracket 49 and pin 50. Since pin 34 is rotatable about its axis independent of the rotation of sleeve 33, overarm 48 may be positioned over either bank arm 32a (as shown), 32b, or 320 (not shown). Thus, it may be positioned over Whichever bank is being paid out for the purpose of controlling pay-out of the coil convolutions as shown in FIG. 5. There overarm 48 rests against the upper surface of bank arm 32 to control the pay-out of coil 24. Drop arm 44 is shown in a dropped position to assist in controlling the pay-out as may be readily seen. When mill coils are placed upon the bank arms (as distinguished from being uncoiled from the arms), overarm 48 is pivoted about the axis of pin 34 and associated with another bank arm (from which uncoiling is progressing) and drop arm .-4 is retracted to a position adjacent bank arm 32.
As mill coils 24 are paid out from bank 27 it is desirable, though not essential, to provide a preliminary descaling station as shown in FIG. 8. The descaling station consists merely of a hard rough surface 51 (roughly surfaced concrete, for example), which is abrasive. As the coil convolutions are pulled in the direction of arrow C and drop onto the surface 51, the impact and abrasion against surface 51 removes a significant portion of the mill scale.
Snarl switch assembly 52 comprises hoop 53 through which the wire is threaded as shown in FIG. 8. Hoop 53 is pivotally mounted to base 54. Conduit 55 is also mounted to base 54 and conducts leads 56 from a switch (not shown) mounted on base 54 toward the precoiling station (where they are connected to the precoiler drive motor circuit so that opening the switch stops the motor). Hoop 53 is pivoted about its vertical axis whenever a snarl prevents passage of the wire W therethrough. The pivoting opens the switch and stops the precoiler motor. Thus, any snarl automatically stops the rewinding process.
The wire W next passes through the straightening and precoiling stations which appear in FIGS. 9 and 10. The straightening station includes bell mouth entry cone assembly 57, straightener 58 and base 59. Entry cone 57 includes entry rollers 60 mounted for rotational movement on four axes respectively which lie in a common plane perpendicular to the direction of travel of the wire W and define a square. Rollers 60a and 60b are mounted to brackets 61a and 6112 respectively. Rollers 60c and 60d are mounted to bracket 61c and 61d respectively. Brackets 61a-d are mounted to brackets 62a and 6212 which is in turn mounted to base 59. Bracket 62b contains an input aperture 64 which has a diameter approximately equal to the diameter of the entry rollers 60 and exposes approximately one-half the diameter of each. Thus, an entry cone is provided for the wire W. Entry rollers 60 are spaced such that they define a square passage having dimensions slightly less than the diameter of wire W. An output aperture sleeve 63 is provided in bracket 62a through which wire W exits. A drag mechanism (not shown) may be provided to inhibit rotation of rollers '60 to produce tension in wire W between entry cone assembly 57 and straightener 58.
Straightener 58 includes frame 65, an upper bank of rollers 66a, 12, and c and a lower bank of rollers 67a-d Therollers 66 and 67 contain a concave peripheral surface which is best seen in FIG. 10 at 68. Rollers 67 are rotatably mounted to frame on shafts 69. Upper bank 66 is rotatably mounted to mounting plates 70. Rollers 66 are vertically adjustable by means of rotation of adjusting screws 7 1. Mounting plates 70 are connected to a common frame member (not shown) which may be raised or lowered by means of lever 72 and. linkage 73 to respectively disengage and engage wire W. The rollers 65 and 66 are horizontally aligned as best seen in FIG. 10. They are vertically staggered as best seen in FIG. 9 to provide a zig-zag passage for'wire W. Thus, as wire W is drawn through rollers 66 and 67, it is reciprocally bent. It will be noted that the degree of bending in successive roller passes may be adjusted by means of adjusting screws 71. As shown at FIG. 9 bending is more extreme 70 upon entry (see rollers 67d and 660) and generally decreases to very little bend in the output rollers 66a and 67a.
The straightener 58 cold works the steel, removes the remaining mill scale and eliminates the bending-moment resiliency induced by the first coiling as'the wire is dead cast from the rolling mill. The cold working also increases the yield point.
Wire W is drawn through straightener 58 by means of precoiler 76 which is mounted to base 59 and forms the precoiling station referred to generally at 74. Precoiler station 74 includes a precoiling motor (not shown) which drives shaft 75 and precoiler 76. Like rollers 66 and 67, precoiler 76 is concave at its circumference which can be best seen at 77 in FIG. 10. It is of sufiicient width or thickness 77 to accommodate two diameters of wire. The precoiling motor is driven at an adjustable speed which remains constant regardless of load. Wire W is wound around precoiler 76 for one convolution and paid out in the direction of arrow D. Friction between wire W and precoiler 76 prevents slippage and precoiler 76 pulls wire W through straightener 58 at a constant speed. Thus, upon its entry to precoiler 76, wire W is under tension. Passage about precoiler 76 induces a bending moment resiliency, and the diameter of precoiler 76 is chosen so that this bending moment resiliency generally tends to hold the wire in a curvature approximately equal to the inner diameter of the finished coil. Precoiler 76 is, of course, aligned with straightener 58 and entry cone assembly 57.
From the precoiler 76 wire W is fed through the guiding station (FIGS. 11 and 12). It passes first between entry rollers 78 and then between gripping rollers 79. Both rollers 78 and 79 are mounted for rotation about the respective entry roller shafts 80 and gripping roller shafts 81. Roller shafts 80 and 81 are mounted in a generally vertical plane but are tilted toward the direction of entry of wire W as best seen in FIG. 12. Gripping roller shafts 81 are mounted at each end to brackets 82 which are in turn rigidly secured to entry roller shafts 80. Gripping roller shafts 81 therefore pivot about the axis of entry roller shaft 80 on brackets 82 as entry roller shafts 80 are pivoted. Entry roller shafts 80 extend through and are journaled in upper plate 83 and lower plate 84 at 85 and 86 respectively. Upper and lower plate 83 and 84 are mounted for reciprocal movement on bars 87 and 88 respectively. This is accomplished through the use of side plates 89 which are rigidly mounted to upper and lower plates 83 and 84 and contain integral mounting brackets 90 and 91 fixed to sleeves 92 and 93 respectively which are slidable along bars 87 and 88 respectively. Thus, the guide and gripping roller assembly is mounted for reciprocal movement on bars 87 and 88 in the direction of arrows E as shown in FIG. 11.
Bars 87 and 88 are mounted in mounting brackets 94 and 95. Mounting bracket 94 is reinforced against tilting by web 96. The mounting brackets 94 and 95 are rigidly secured to frame 97. Canvas bellows 98 are provided on a coil spring skeleton 99 to serve as a dust cover in the area of bars 87 and 88 not covered by sleeves 92 and 93.
Studs 100 are fixed to upper plate 83. Bolts 101 extend through studs 100 and are spring loaded against nut 102. The ends of bolts 101 opposite nut 102 are pivotally connected to arms 103. Arms 103 are rigidly connected to entry roller shafts 80. Thus, as nuts 102 are loosened or tightened, arms 103, entry roller shaft 80, brackets 82, gripping roller shaft 81 and gripping roller 79 is pivoted about the axis of entry roller shaft 80. The spring mounting of bolts 101 also holds gripping rollers 79 resiliently against wire W and, together with stud 100, provides a method for adjusting the spacing between gripping rollers 79 to accommoate various wire diameters.
Guide roller brackets 104 and 105 are mounted on upper plate 83 and lower plate 84 respectively. Guide rollers 106 and 107 are mounted for rotational movement on shafts 108 and 109 respectively which in turn are mounted to brackets 104 and 105. Guide rollers 106 and 107 serve to limit the vertical traverse of Wire W to somewhat less than the length of entry and gripping rollers 78 and 79.
Pawl housing 110 is mounted to the lower side of lower plate 84 and envelops worm gear shaft 111. Pawl 112 is removably mounted in pawl housing 110 and engages the track of worm gear shaft 111 which is mounted for rotational movement in mounting bracket 94 and bearing 113. Worm gear shaft sprockets 114 is linked with gear reducer sprocket 115 by means of chain 116. Gear reducer 117 is mounted to frame 97 and power is supplied to sprocket 118 from a power source not shown. Thus, as worm gear shaft 111 is rotated, pawl 112 follows the worm gear track and as a result, reciprocates pawl housing 110. The gripping and roller assembly thereby reciprocates on bars 87 and 88 as shown by arrow B in FIG. 11. The traverse of pawl 112 and as a result gripping rollers 79, is equal to the width of the take-up reel 119 minus the diameter of the wire. The speed of rotation of worm gear shaft 111 is coordinated with the speed of rotation of the take-up reel through gear reducer 117, to insure a level wound finished coil. In addition gear reducer 117 adjusts the speed of worm gear 111 to compensate for a change in the wire diameter due to the winding of various diameter wires from time to time.
After passing through the guiding station, wire W proceeds to the winding station (FIGS. 13 and 14) where it is wound on take-up reel 119a. The winding station includes frame 120 to which is mounted turntable motor 121 and take-up reel motor 122. Turntable shaft 123 is journaled on frame 120 in bearings 124. A turntable sprocket 125 is rigidly secured to one end of turntable shaft 123 and linked by chain 126 to sprocket 127 of turntable motor 121. Turntable arms 128a and 128b extend radially from turntable shaft 123 and are rigidly secured thereto. Thus, as turntable shaft 123 is rotated in bearings 124 by motor 121 and chain 126, turntable arms 128 sweep in the direction of arrow F in FIG. 13.
The ends of turntable arms 128 contain sleeves 129. They are rigidly secured to arms 128 having their axes parallel to the axis of turntable shaft 123. Reel shafts are mounted in sleeves 129 for rotation therein and extend beyond one end of sleeves 129 terminating at a threaded engagement with wing nuts 131. The opposite end of shaft 130 terminates at joint 132.
Take-up reel motor sprocket 133 is linked by chain 134 to reel drive sprocket 135. Reel drive shaft 136 extends rigidly from reel drive sprocket and is journaled in bearing 137 and terminates at universal joint 132, at that point being fixed to reel shaft 130a. Joint 132 is capable of quick assembly and disassembly to connect drive shaft 136 to reel shaft 130 and to sever the connection respectively by hydraulically shifting shaft 136 along its axis. When shifted to abut reel shaft 130 as shown in FIG. 14 joint 132 is engaged and the rotation of shaft 136 rotates reel shaft 130. The joint is hydraulically disengaged when reel 119a is removed from the take-up position and an empty reel takes its place.
Lock arm 138 is pivotally connected to lock arm bracket 1380 which is mounted to frame 120. Look arm 138 is two-sided as may be seen by reference to side 138a and 138b in FIG. 14. Each side is arcuately notched to a depth equal to the outside radius of sleeve 129. It therefore accommodates sleeve 129 and locks turntable arms 128 in the position shown in FIG. 13 and prevents sweeping movement in the direction of arrow F. Thus, arms 128 and reel 119a are locked in a take-up position with shaft 130a aligned with reel drive shaft 136. The positions are simultaneously interchangeable by disengaging lock arm 138 and sweeping turntable arms 128 one hundred eighty degrees. Lock arm 138 is engaged and disengaged with sleeve 129 by means of hydraulically operated jack 139 which is fixed at one end to guiding station frame 97 and at the other end to lock arm 138.
Take-up reels 119 are mounted for rotation on reel shafts 130. Reels 119 consist of spool 140, permanent flange 141 and removable flange 142. Spool 140 is keyed to reel shaft 130. Both flanges 141 and 142 as well as spool 140 contain slots 144 which are radially positioned and spaced one hundred twenty degrees from one another. Flange 142 is removable by removing wing nut 131.
The winding station is aligned with the guiding station so that a line passing through a plane equidistant from reel flanges 141 and 142 perpendicularly bisects the tra verse of entry and gripping rollers 78 and 79.
The description of the apparatus utilized in the specific embodiment is then complete except for the variation in the design of the flipper or star-wheel which appears in FIG. 7. The design shown there difiers from the design of FIGS. and 6 because overarm 48 and drop arm 44 are eliminated and a jointed bank arm 232 is added. Bank arm 232 contains joint 233 which is pivotable about pin 234 in the direction of arrow G. Thus, bank arm 232 has two positions with respect to vertical arm 231. One position is perpendicular to arm 231 for placement of mill coils thereon and the other position is parallel to arm 231 for pay-out. Bank arm 232 is pivoted about pin 234 by means of hydraulic linkage 235 which is pivotally connected at one end to arm 232 and at the other end to vertical member 231 as shown in FIG. 7. Thus, by placing bank arm 232 in a vertical position, mill coil convolutions may be paid out vertically so as to take advantage of gravity to prevent snarling more effectively than is possible with the previously described star-wheel.
Having thus described the apparatus of the specific embodiment the operation is readily apparent. Mill coils are received and passed through the trimming, welding, flipping, descaling, straightening, precoiling, and guiding stations where wire W is handled and processed as previously described. The end is then fixed to spool 140 and take-up drive motor applies a constant torque to reel drive sprocket 135 to turn reel 119 and Wind wire W thereon. The take-up reel speed is a function of the precoiler speed and the outside diameter of the finished coil at any given moment. The guiding station operates at a speed which is directly proportional to the speed of take-up reel 119a.
After the reel is filled, the coil is steel-strapped by inserting steel straps 143 into slots 144 and circumscribing the radial section of the finished coil 145. Turntable arms 128 are then actuated and the position of reel 11% is interchanged with reel 11%. Reel 119a is thus swept into an unloading position and reel 119/5 is swept into a take-up position. Winding is begun on reel. 11% as previously done on reel 119a. On repositioned reel 119a, wing nut 131a is removed along with flange 142 to expose finished coil 145. Coil 145 is removed from spool 140 and the process has produced one unit.
The finished coil which appears in FIG. 15 is tightly and level wound as may be seen with reference to the radial cross-section. It is compact, which is desirable for storage and transport, and free of mill scale. After the retaining straps are cut it may be smoothly paid out by rotation about its axis (on an A-frame for example). It is therefore, unlike the dead cast mill coil, a suitable raw material for subsequent automatic or manual manufacturing processes in various industries.
Having thus described my invention, I claim:
1. A continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another, securing an end of one of said individual coils to the compatible end of the adjacent coil thereby making said individual coils continuous, uncoiling said continuous individual coils, reciprocally bending said wire, passing said wire under tension about a precoiler and continuously removing said wire therefrom, reciprocally guiding said wire for level winding about a reel in a take-up position, rotating said reel with constant torque and winding said wire about said reel to form said coil.
2. A continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another to form a first bank of coils having a longitudinal axis extending radially from a substantial vertical axis, sweeping said first bank arcuately about said substantially vertical axis, securing an end of one of said coils to the compatible end of the adjacent coil, placing a plurality of said individual coils adjacent one another to form a second bank of coils having a longitudinal axis extending radially from said vertical axis, sweeping said banks arcuately about said substantially vertical axis, securing one end of the coil in said first bank nearest said vertical axis to the compatible end of the coil in said second bank farthest from said vertical axis, securing an end of one of said coils in said second bank to the compatible end of the adjacent coil, again placing a plurality of said individual coils adjacent one another to form a third bank, securing one end of the coil in said second bank nearest said vertical axis to the compatible end of the coil in said third bank farthest from said vertical axis, securing an end of one of said coils in said third bank to the compatible end of the adjacent coil, uncoiling said first bank, reciprocally bending said wire, passing said wire under tension about a precoiler and continuously removing said wire therefrom, reciprocally guiding said wire for level winding about a reel in a take-up position, rotating said reel with constant torque thereby winding said wire about said reel to form said wire coil.
3. The method of claim 2 further characterized by securing said wire coil about a plurality of radial crosssections equally spaced on the circumference thereof, severing said wire, removing said reel with said secured coil thereon from said take-up position and simultaneously replacing said reel, removing a flange of said reel and removing said secured coil therefrom.
4. The method of claim 2 wherein said third bank is inclined upwardly in the direction of said uncoiling.
5. The method of claim 2 wherein said first bank is arcuately swept in a vertical plane prior to uncoiling therefrom, said uncoiling proceeding in a substantially vertical direction.
6. A continuous method for making wire coils from shorter individual coils which comprises: placing a plurality of said individual coils adjacent one another with the ends of said coils hanging symmetrically beneath said coils and crossing the adjacent end of the adjacent coil to form a first bank of coils having a longitudinal axis extending radially from a substantially vertical axis, sweeping said first bank arcuately about said substantially vertical axis, abutting and securing an end of one of said coils to the adjacent compatible end of the adjacent coil, placing a plurality of said individual coils adjacent one another with the ends of said coils hanging symmetrically beneath said coils and crossing the adjacent end of the adjacent coil to form a second bank of coils having a longitudinal axis extending radially from said substantially vertical axis, sweeping said banks arcuately about said substantially vertical axis, abutting and securing one end of the coil in said first bank nearest said substantially vertical axis to the compatible end of the coil in said second bank farthest from said vertical axis, abutting and securing one end of said coils in said second bank with the adjacent compatible end of the adjacent coil, again placing a plurality of said individual coils adjacent one another to form a third bank similar to said first and second banks, sweeping said banks arcuately about said substantially vertical axis, abutting and securing one end of the coil in said secand bank nearest said substantially vertical axis to the compatible end of the coil in said third bank farthest from said substantially vertical axis, abutting and securing one end of said coils in said third bank with the adjacent compatible end of the adjacent coil, uncoiling said first bank in a direction corresponding to the longitudinal axis of said bank, passing said wire over and in contact with an abrasive surface, reciprocally bending said wire, passing said Wire under tension at a constant speed about a precoiler and continuously removing said Wire therefrom, reciprocally guiding said wire for level winding about a reel in a take-up position, rotating said reel with constant torque thereby winding said wire about said reel to form said wire coil, securing said wire coil about a plurality of radial cross sections equally spaced on the circumference thereof, severing said wire, removing said reel and coil from said take-up position and simultaneously replacing said reel, and removing a flange of said reel and removing the secured finished coil therefrom.
7. The method of claim 6 wherein said third bank is inclined upwardly in the direction of said uncoiling.
8. The method of claim 6 wherein said first bank is arcuately swept in a vertical plane prior to uncoiling therefrom, said uncoiling proceeding in a substantially vertical direction.
9. Apparatus for making wire coils from shorter individual coils which comprises, in combination: a starwheel having a substantially vertical elongate member mounted for rotation about its axis and three elongate arms equally spaced and radially mounted thereto, an entry cone roller assembly including four rollers mounted with their axes in a vertical plane and defining a square, said rollers forming a square passage having a dimension substantially equal to the diameter of said wire, a straightener having an upper bank of rollers and a lower bank, said rollers being circumferentially concave and horizontally aligned but vertically positioned with said upper bank intermeshed with said lower bank, a precoiler having a circumferentially concave surface and means for driving said precoiler at a constant speed, a guiding mechanism having a pair of substantially vertically positioned entry rollers and gripping rollers, said entry rollers being spaced a distance substantially equal to the diameter of said wire, and said gripping roller mounted for arcuate movement about said entry rollers and means for urging said gripping rollers toward each other to thereby grip said wire, and means for reciprocally traversing said rollers, a winding station including a turntable arm having a reel rotatably mounted on each end, means for sweeping said arm about an axis perpendicular to its longitudinal axis and means for locking said arm with one of said reels in a take-up position, said entry cone rollers assembly, straightener, precoiler, guiding mechanism, and winding station being horizontally aligned.
References Cited UNITED STATES PATENTS 2,511,274 6/1950 Kramer 1401 2,929,569 3/ 1960 Detrick 242-25 2,971,709 2/ 1961 Ellis 242-25 3,002,537 10/1961 Kenmore et al. 140--1 3,026,053 3/ 1962 Sisson et al. 242--25 CHARLES W. LANHAM, Primary Examiner.

Claims (1)

1. A CONTINUOUS METHOD FOR MAKING WIRE COILS FROM SHORTER INDIVIDUAL COILS WHICH COMPRISES: PLACING A PLURALITY OF SAID INDIVIDUAL COILS ADJACENT ONE ANOTHER, SECURING AN END OF ONE OF SAID INDIVIDUAL COILS TO THE COMPATIBLE END OF THE ADJACENT COIL THEREBY MAKING SAID INDIVIDUAL COILS CONTINUOUS, UNCOILING SAID CONTINUOUS INDIVIDUAL COILS, RECIPROCALLY BENDING SAID WIRE, PASSING SAID WIRE UNDER TENSION ABOUT A PRECOILER AND CONTINUOUSLY REMOVING SAID WIRE THEREFROM, RECIPROCALLY GUID-
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Cited By (2)

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Publication number Priority date Publication date Assignee Title
US3443607A (en) * 1967-01-04 1969-05-13 Malmedie & Co Maschf Wire straightener
US10690481B2 (en) * 2018-11-28 2020-06-23 Innovatech, Llc Measuring apparatus and method for measuring flexible elongated parts

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US2511274A (en) * 1946-04-11 1950-06-13 American Steel & Wire Co Method of straightening and coating wire
US2929569A (en) * 1957-02-26 1960-03-22 Western Electric Co Continuous wire winding apparatus
US2971709A (en) * 1957-05-03 1961-02-14 Western Electric Co Apparatus for continuously reeling strand material
US3002537A (en) * 1954-05-27 1961-10-03 Nat Standard Co Machine for continuously treating heavy wire and similar strip material
US3026053A (en) * 1960-11-04 1962-03-20 Franklin Res And Dev Corp Crossover stock cutting device in multi-reel winding apparatus

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Publication number Priority date Publication date Assignee Title
US2511274A (en) * 1946-04-11 1950-06-13 American Steel & Wire Co Method of straightening and coating wire
US3002537A (en) * 1954-05-27 1961-10-03 Nat Standard Co Machine for continuously treating heavy wire and similar strip material
US2929569A (en) * 1957-02-26 1960-03-22 Western Electric Co Continuous wire winding apparatus
US2971709A (en) * 1957-05-03 1961-02-14 Western Electric Co Apparatus for continuously reeling strand material
US3026053A (en) * 1960-11-04 1962-03-20 Franklin Res And Dev Corp Crossover stock cutting device in multi-reel winding apparatus

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3443607A (en) * 1967-01-04 1969-05-13 Malmedie & Co Maschf Wire straightener
US10690481B2 (en) * 2018-11-28 2020-06-23 Innovatech, Llc Measuring apparatus and method for measuring flexible elongated parts
US11067384B2 (en) 2018-11-28 2021-07-20 Innovatech, Llc Measuring apparatus and method for measuring flexible elongated parts

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