Tlnited States Patent [191 Richley Feb. 5, 1974 ADJUSTABLE QUHL AND QUILL HEAD MOUNTING THEREFOR [75] Inventor: Joseph L. Richley, Williamsport, Pa.
[73] Assignee: Bethlehem Steel Corporation,
Bethlehem, Pa.
[22] Filed: June 14, 1972 [21] Appl. No.: 262,813
[52] US. Cl. 57/55, 57/138 [51] Int. Cl. D07!) 3/00, DOlh 13/04 [58] Field of Search 57/9, 138, 55, 34 R [56] References Cited UNITED STATES PATENTS 2,124,864 7/1938 Weller 57/9 2,309,384 1/1943 Downing 57/138 2,366,593 1/1945 Cantrell et al. 57/138 2,374,133 4/1945 Ramstedt 57/138 X 2,882,676 4/1959 Bryan et al. 57/138 3,446,000 5/1969 Smollinger et al 57/138 Primary ExaminerDonald E. Watkins [5 7 ABSTRACT An adjustable quill has a tubular housing, in both ends V I A of which semicircular disks are adjustably mounted. The relative positions of the edges of the said disks serve to define opposite ends of a spiral preforming path for a wire strand being drawn through the tubular housing. The spiral preforming path within the housing between the adjustable end disks follows the outer circumference of a cylindrical structure extending between the two end disks and comprised, in a preferred embodiment for some purposes, of a series of rotatable disks, or, alternatively, for other purposes, of an extended rod or tubular member.
In some embodiments the tubular housing for the adjustable quill may be omitted if a specially designed quill head is used to mount the quills.
A quill head for adjustably mounting the adjustable quills is also disclosed to be formed from a series of circular plates mounted upon a shaft. The plates have apertures into which the adjustable quills are mounted. A chain and sprocket arrangement may provide uniform adjustment between the adjustable end disks of a series of adjustable quills mounted in the plates of the quill head.
14 Claims, 13 Drawing Figures PAIENTEMB 5 e914 SHEU 1 0F 3 ADJUSTABLE QUIILL AND QUILL HEAD MOUNTING THEREFOR BACKGROUND OF THE INVENTION The present invention relates to the fabrication of wire rope and strand and more particularly to the fabrication of preformed wire rope and strand and improved apparatus for accomplishing such fabrication.
Wires or strands of wire are very frequently preformed immediately prior to closing, i.e. laying or twisting together within a closing die, a number of the wires or strands into a twisted wire strand or rope. Preforming is customarily accomplished either in a roller type preforming head or a so-called quill head. Conventional quill heads are provided with circular orifices extending longitudinally through the head. So-called quills are inserted into these orifices to accomplish the actual preforming of the wires or wire strands. The quills are comprised of solid rods of hardened steel,
such as tool steel or the like, into the outer surface of which there is machined a helical groove having a width and depth sufficient to accommodate the desired wire or strand. (Such wire or wire strand will hereinafter at times be designated for convenience broadly as linear material or wire linear material). The grooves in the quill rods have a helical configuration such that a wire or strand which is constrained to follow the same helical path will be stressed beyond its elastic limit and will be permanently preformed, or deformed, into a similar though somewhat larger helical configuration which is predetermined to conform to the helix of the respective wires or wire strands in the wire strand or rope-which is being fabricated.
In setting up a closing apparatus for fabricating a preformed wire rope or strand using a quill head, the individual wire strands or wires must be initially forced at least partially into the helical grooves in the quills and held within the grooves until each quill is inserted into its proper orifice within the quill head and adjusted to its proper rotational position. Placement of very small wires or strands within the groove of the quill presents little problem, but as the size and strength of the wire or strand increases the effort required to force it into the grooves of the quills rapidly increases. In the larger sizes of wire ropes the effort required to force the component strands into the groove of the quill would literally tax the strength of a squad of gorillas. As may be imagined it is quite difficult to employ competent workmen to perform such labor. Usually, therefore, in the fabrication of large diameter wire ropes the individual strands are heated with a torch to anneal or soften a leading portion of the strand so that it may be forced into the grooves of the quill before placement within the quill head. Even with such heating, however, the proper placement of large wire strands within the quill is an extremely difficult, ticklish, unpleasant and at times almost superhuman task.
Since each quill, as conventionally constructed, is formed from a solid rod with machined grooves in its outer surface, a separate set of quills must be on hand for each type and size of rope or strand which is to be preformed during fabrication. These quills are not usually interchangeable even between right and left hand rope or strand of the same type and size. The quills, moreover, are subject to wear and upon serious wear occurring new quills must be machined. Moreover, if
the configuration of the grooves in the quills do not turn out to be correct for the particular rope or strand which is being fabricated, they cannot be adjusted and instead completely new quills must be machined, resulting in considerable delay and additional expense.
Conventional type quill heads have also usually been especially constructed for use in fabricating particular ropes and types of ropes and strands, although quill heads have in general been more interchangeable than the quills designed to be inserted into the quill heads. The problems arising with conventional fixed quill heads have been previously alleviated by the invention of an adjustable quill head as disclosed in U. S. Pat. No. 3,446,000 granted May 27, 1969 to C. W. Smollinger et al. This adjustable quill head has enabled fine adjustments to be made in the relative position of individual quills with respect to each other for the proper placement during closing of different operations, or layers, of a single wire rope, particularly in so-called interlocked type wire rope. The problem of making individual or fine adjustments to the helices of the quills themselves has, however, remained a serious problem. In addition the individual quills in each quill head have had to be individually adjusted with respect to their rotational position within conventional quill heads.
SUMMARY OF THE INVENTION The foregoing problems associated with the permanent nature of the helices machined into conventional quills have been obviated by the adjustable quill constructed according to the present invention. The quills of the instant invention are comprised of at least two adjustable disks situated at opposite ends of the quill and designed to bias the wire or wire strand in opposite directions as it passes by said disks so that the wire or strand assumes the form of a helix passing about a central supporting member between the ends of the quill. The spiral angle of the helix of strand is determined by the relative positions of the defining disks at each end of the helix. The angles of the helices may be easily changed by altering the relative position of the disks so that the quills may be used interchangeably for preforming wires and strands for different constructions of strands and ropes. This interchangeability is a great convenience in a busy production shop. Adjustments in the angle of the preforming helix may additionally be made as their desirability may become evident during production without having to machine new quills or removing and replacing the preforming head. Adjustments can even be made to the helix angle of the quills in the middle of a long piece of rope which is being fabricated without damage to the rope. In addition, because of the nature of the quill, a wire or strand may be easily positioned in the quill of the invention without undue effort. Where, as preferred, the quill includes an integral outer cylindrical or tubular housing, or the quill is mounted in a special quill head, the strand or wire may be initially strung through the housing and then biased into the proper helical position by merely twisting the helix defining disks into proper position and locking them in the proper position.
The improved adjustable quill of the invention, which can be used in conventional quill heads, is also adapted to be used with an adjustable'quill head which constitutes another aspect of the applicants invention. In the adjustable quill head the quill is substantially integrally mounted within the quill head and means is preferably provided to adjust the helix angles of a plurality of quills simultaneously through the action of coordinated drive means mounted upon the quill head. The quill head of the invention is preferably constructed of a series of relatively thin metal plates mounted transversely upon a rotatable shaft which will usually be an extension of the shaft of a rotating cage or framework of a closing machine. The plates are provided with opposed recesses in which the adjustable disks or the housing of the quills are mounted. A mechanical connection may be provided between the various adjustable disks in the mounting quill head so that all the disks in a group of disks can be adjusted as a unit to the same helix defining angles. The quill head of the invention is much cheaper to construct and lighter than conventional solid quill heads and does not require special lifting and handling equipment to mount and dismount upon a closing apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of an adjustable quill according to the present invention.
FIG. 2 is a cross-section through the quill shown in FIG. 1.
FIG. 3 is an exploded view of the adjustable quill shown in FIG. 1.
FIG. 4 is a partially broken away view of an alternative embodiment of the adjustable quill of the present invention.
FIG. 5 is an exploded view of the adjustable quill shown in FIG. 4.
FIG. 6 is a partially broken away view of another alternative embodiment of the adjustable quill of the present invention.
FIG. 7 is an exploded view of the adjustable quill shown in FIG. 6.
FIG. 8 is a cross-sectional view of a conventional quill head with the adjustable quills of the present invention inserted therein in operating position.
FIG. 9 is an elevation of an improved quill head according to one aspect of the present invention designed to mount the adjustable quills of the invention.
FIG. 10 is an elevation of a quill adapted for use particularly in the quill head of FIG. 9.
FIG. 11 is an elevation of the end of the quill shown in FIG. 10.
FIG. 12 is an elevation of an adjustable quill head according to one aspect of the present invention.
FIG. 13 is an end elevation of the adjustable quill head shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIGS. 1, 2 and 3 there is shown one embodiment of the adjustable quill 11 of the present invention comprising a tubular housing 13 having mounting screw holes 15 at both ends tapped for machine screws 17 which serve to secure ring stops 19 and 21 to the housing 13. Positioned within the housing 13 against ring stop 21 is adjustable entrance disk 23 and at the opposite end of the housing 13 is the adjustablw exit disk 25. A series of freely rotatable disks 27 are positioned or stacked between the two outer adjustable disks 23 and 25. Threaded set screw openings 29 are provided at both ends of the tubular housing 13 in a position to allow threaded set screws 31 to be screwed partially through the housing 13 and into contact with the adjustable disks 23 and 25 positioned just inside the ends of the housings 13. Two wrench holes 33 are positioned at a predetermined distance from each other in the adjustable disks 23 and 25. These wrench holes are adapted for insertion of a spanner wrench to facilitate revolution of the disks 23 and 25 within the housing 13 to a preselected position. Each of the disks 23, 25 and 27 is made up of two principal sections, a central section 35 which may be conceived as comprising a central circuit, root, and an outer truncated ring section 37 of the disk. A portion of the central circular root 35 projects into the truncation 38 of the outer ring section 37.
Preferably the inner edges 39 of the ring section 37 of the disks 23 and 25 are hardened in any suitable manner such as by quench hardening, stelliting or by reason of the entire disk being made of a work hardenable steel or the like. The edges are also preferably reduced in thickness and the edges are tapered to reduce frictional surface contact with linear material passing said edges.
FIGS. 4 and 5 depict an alternative embodiment of the quill of the invention. In these FIGURES a quill 40 is comprised of a cylindrical or tubular housing 41 having mounting screw holes 43 into which machine screws 45 are threaded to hold ring stops 47 and 49 to opposite ends of the housing 41 to prevent an entrance disk 51 and exit disk 53 similar to the entrance and exit disks 23 and 25 in FIGS. 1 and 2 from sliding from the housing 41. Both exit and entrance disks 51 and 53 have journal holes 55 centered in a root section 57 of the disks. Extensions S9 of a central shaft 61 extend into the journal holes so that the disks 51 and 53 are rotatably mounted upon the ends of the shaft 61 within the housing 41. Shaft 61 is preferably formed from a solid rod of hardened steel for reasons which will appear below. The shaft 61 is preferably also substantially the same diameter as the root sections 57 of the disks 51 and 53. Disks 51 and 53 each have spanner wrench orifices 63 suitably within them for insertion of a wrench to rotationally position the disks 51 and 53 within the housing 41. Set screws 65 are rotatably mounted within the housing 41 in threaded orifices 67 to hold the disks 51 and 53 in position within the ends of the housing 41.
Preferably the inner edges 69 of the ring portion 58 of the disks 51 and 53 are hardened in some suitable manner for wear resistance and are reduced in thickness and tapered to reduce surface contact with linear material passing the disk and bearing upon the said edges.
In FIGS. 6 and 7 there is shown still a further embodiment of the invention. The identifying numerals in FIGS. 4 and 5 and FIGS. 6 and 7 are identical where they refer to identical structures. In FIGS. 6 and 7 only the adjustable entrance and exit disks 71 and 73 are constructed in a different manner from the parts of the quills illustrated in FIGS. 3 and 4. The disks 71 and 73, in place of the root and ring portions of the disks 51 and 53 in the preceding FIGURES, are comprised of a more or less solid disk into which is machined a guide groove 74. The guide groove 74 may be considered as being a modified truncation of an outer ring portion of the disk. The bottom of the guide groove 74 then just touches a central circular portion of the disk which may be considered as constituting a control root portion of the disk. The edges 75 of the guide grooves 74 are preferably hardened in any suitable manner such as by quenching or by the application of a stellite outer layer to render them more wear resistant. The edges are also preferably somewhat tapered to decrease the frictional surface contact of a strand passing through the guide groove 74 with the respective disks.
In FIG. 8 there is shown a cross sectional elevation of a more or less conventional quill head having the quills of the invention as embodied in FIGS. 4 and 5 or 6 and 7 inserted therein in operating position. In F16. 8 a central or core strand 81 passes centrally through the hollow center of the quill head 85 and the extension 87 of the shaft of the rotatable cage of the closing apparatus, not shown, into a closing die 89. At the same time six outer operation strands 91 pass through quills 40 to the closing die 89. Each of the outer operation strands 91 is initially threaded through the housings 41 of the quills 40 past or through the entrance disks 51 or 71 and the exit disks 53 or 73 and into the closing die. The strands 91 are initially threaded straight through the adjustable quills 40 while the entrance and exit disks are aligned with each other within the tubular housings 41. After the strands are threaded through the quills 40, one or the other of the end disks are locked in place by screwing the set screws 65 into the tubular housing until they forcibly contact the edge of the end disks. The adjustable disk at the opposite end of the housing 41 from the locked disk is then rotated by placing a spanner wrench within the wrench orifices 63 and rotating the disks until the strand is wrapped about the rod 61 sufficiently to attain the degree of preforming desired in the strand. The appropriate set screws 65 are then set to lock this disk in place. The two end disks in their locked positions define two ends of a spiral prestressing path through which the strand passes to attain a preforming set effective to cause the strand to assume a configuration suitable for inclusion within'the rope being closed without any stress or strain in the individual strands.
FIG. 9 shows an embodiment of a special quill head designed to accommodate the quills of the invention. In FIG. 9 there is shown a central or core strand 101 passing centrally through an extension 103 of the shaft of a rotating cage, not shown, of a conventional stranding machine. Secured to the shaft extension 103 by a series of brackets 105 are three circular plates 107, 109 and 1 1 1 extending perpendicularly from the shaft extension 103. ,Plate 107 has a series of wear resistant strand guides 113 mounted in it. The guides 113 serve to guide outer operational strands 114 from the cage not shown of the stranding machine to the preforming quills 115 of the present invention mounted in plates 109 and 111. Each quill 115 is comprised of a central shaft 117 which extends between an entrance disk 119 and an exit disk 121 mounted in recesses 123 and 125 in opposite sides of the plates 109 and 111 respectively. Any suitable type of locking device may be provided to lock the disks 119 and 121 in place within the plates after they are adjusted to the correct rotational position for the desired prestressing of the outer strands 114. A wing nut type set screw 127 is shown in FIG. 9 threaded into the outer rims of the plates 109 and 111 and contacting the edges of the disks 1 19 and 121 to lock them in position within the recesses 123 and 125. The recesses 123 and 125 extend completely through the respective plates 109 and 111, but preferably have two inside diameters. The larger diameter 129 of each recess is sufficient to accommodate the outside diameter of the respective disks 119 and 121 while the smaller diameter 130 is sufficiently wide to prevent rubbing of the strands 114 against the side of the recess as the strands pass through the preforrning quill, but not wide enough to allow the disks 119 or 121 to pass completely through the recess.
The quills 115 used in the quill head do not have or require an outer tubular housing as shown in FIGS. 1 through 8 because they are designed to fit closely into the quill head 100 which is especially designed to accommodate them. The quills are thus constructed essentially as shown in FIGS. 9, 10 and 11 with a central shaft 117, an entrance and exit disk 119 and 121 which disks are substantially interchangeable with each other and guide grooves 131 in the disks to guide the outer operational strands of the rope. The guide grooves 131 are similar to the guide grooves 74 in the disks shown in FIGS. 6 and 7 and the structure of the disks are otherwise also substantially similar. The disks 119 and 121 are also rotatable upon the ends of the shaft 117 and have wrench holes 133 adapted for use with a spanner wrench to turn the disks into the desired position with respect to each other.
When mounting the quills 115 in the quill head 100 one of the adjustable disk 1 19 or 121 are removed from the shaft 117 while the remainder of the quill assembly is mounted in the quill head recesses. The removed disk is then replaced upon the shaft 117 and in position within its respective recess in the plates 109 or 111. One of the outer operational strands 114 is then threaded through the guide 113, through the guide ori fice 131 in the entrance disk 1 19, through the guide orifice 131 in exit disk 121 and then into the closing die 135 of the stranding machine. A spanner wrench is then applied to the wrench holes 133 of the respective disks to rotate the disks upon the shafts 117 to position the disks at angles with respect to each other suitable to properly preform the outer operational strands 114 by wrapping these strands about the shaft 117 a desired amount. When the disks attain their correct positions, they are locked into said correct positions by rotating the set screws 127 into jamming contact with the edges of both the disks 119 and 121. If desired the outer edges of the disks may be serrated or have closely spaced holes or depressions in their surfaces as shown in FIG 10 to accommodate the end of the set screws and provide a more secure interlocking action with the set screws.
In FIGS. 11, 12 and 13 there is shown a modification of the quill head shown in FIG. 9. The same reference numerals are used in FIGS. 9, 10, 11, 12 and 13 to refer to identical structures. In FIG. 12 the adjustable disks 119 and 121 of FIGS. 9, 10 and 11 are replaced by sprocket disks 137 and 139. These disks are rotatably journaled upon the ends of a central shaft 1 17 as shown in FIGS. 9 and 10. The disks 137 and 139 are somewhat thicker than the disks 119 and 121 in the previous figures and are provided upon their outer edges with sprocket rings 141 extending beyond the edge of the larger diameter section 192 of each of the recesses 123 and 125. A sprocket chain 143 extends around the outside of the sprocket rings 141 as best shown in FIG. 13 so that rotation of one sprocket ring results in rotation of the remainder of the sprocket rings 141 and the attached adjustable disks 137 and 139 to the same extent. A ratchet-type sprocket wheel 145 and lever 147 arrangement serves to drive the sprocket chain 143 and interengaged sprocket rings 141 and attached disks 137 and 139 into their desired position. The ratchets 151 are spring engaged with the sprocket wheel 145 to lock the mechanism when the correct position is reached. During movement of the sprocket mechanism one or the other of the ratchets 151 are manually pulled away from the sprocket wheel 145 by means of handles 153 to allow the sprocket wheel 145 to rotate in the desired direction.
The guide grooves 74 and 131 as seen in FIGS. 6, 7 and 11 for guiding the outer operational strands of the rope through the adjustable quills are in the sprocket disks 137 and 139 abbreviated into circular or arcuate guide orifices 149 in order to avoid interference with the outer sprocket rings 41.
In H65. 12 and 13 only the sprocket rings and chain mounted upon the exit disks 137 mounted upon plate 111 are shown. It will be understood, however, that the same type of disk drive arrangement may be provided upon the entrance disks 139 mounted upon the plate 109. It is not necessary to have the same mechanical drive arrangement connected to the adjustable disks on both of the plates, since it is generally necessary in adjusting the disks to provide the correct preforming of strand or wire to merely rotate the disks on one plate, which will usually be the entrance disks on plate 109, into a constant position where they are locked in place by the set screws 127 and then after the strand or wire is threaded through the quills rotate the other set of adjustable disks into the correct preforming position. Usually the exit disks will be rotated to set the preforming angle for the strand while the entrance disks are locked into position and left there.
In the quill embodiment shown in FIGS. 1 and 2 the strand or wire after it is threaded through the quill will ride against the central root section of the disks. The central freely rotatable disks 27 will be rotated into position by the strand or wire as the ring portions 37 of the end disks 23 and 25 are rotated against the strand so that the strand lies against the root 35 of all the disks in the same manner as it rides against and about the solid shaft between the disks in the other embodiments shown in the various FIGURES. Since there is a considerable stress placed upon the central guide shaft by the pressure or force of the strand bearing against it, the shaft must be very strongly constructed. The use of the freely rotatable central disks therefore has some advantages in that the stress of the strand against the root section of the disks is evenly transferred into the outer ring portions of the disks and transferred to the walls of the housing 13 and into the surrounding quill head when a conventional quill head is used. The disks are thus stronger than a comparable shaft and for that reason are advantageous with certain sized strands where the central shaft must be relatively small with respect to the strand size. The disks are also more efficient in conducting heat away from the central guide section than is a separate shaft. On the other hand it has been found that with some strands and wires, and particularly with strands and wires coated with an outer metallic coating or the like, small particles may rub off the strand or wire and fall between the freely rotatable disks, jamming the disks into position and interfering seriously not only with adjustment of the disks during set up of the apparatus but also adjustment of the disks during operation to adjust for variations in operations or slight errors in the original set up of the apparatus.
I claim:
1. A preforming device for wire linear material comprising:
a. a supporting structure,
b. a tubular housing mounted upon the supporting structure,
c. two outer disks adjustably mounted within said tubular housing and spaced from each other, each disk comprising a central solid root section and an outer truncated ring section circumferentially disposed about the inner root section, at least one of said disks being mounted for rotational adjustment with respect to the other disk to define the two ends of a spiral configuration of linear material,
d. guide means extending between the roots of the two respective disks and having a diameter substantially similar to the diameters of the two roots of the two said disks.
2. A strand preforming apparatus according to claim 1 wherein the guide means of (d) comprises a series of freely floating disks held within said tubular housing of (b), each said disk having a root section substantially similar in diameter to the root section of the two said outer disks and an outer discontinuous disk section, each disk being mounted to allow free rotational movement within said tubular housing within said outer disks.
3. A strand preforming device according to claim 1 wherein the guide means of (d) is comprised of a rigid cylinder extending between the roots of the two said disks.
4. A strand preforming device according to claim 3 wherein the outer ring section of said outer disks of (c) have a narrow sector shaped truncation the edges of which define a guide groove for linear material passing through said preforming device.
5. A strand preforming device according to claim 4 in which the supporting structure of (a) comprises a substantially solid rotatable mounting having a cylindrical orifice into which said tubular housing of (b) is inserted.
6. A strand preforming device according to claim 5 in which the supporting structure has a plurality of cylindrical orifices arranged in a pattern into which are inserted a plurality of the tubular housings of (b).
7. A strand preforming device according to claim 1 in which the supporting structure of (a) comprises a substantially solid rotatable mounting having a cylindrical orifice into which said tubular housing of (b) is inserted.
8. A strand preforming device according to claim 7 in which the supporting structure has a plurality of cylindrical orifices arranged in a pattern into which are inserted a plurality of the tubular housings of (b).
9. A strand preforming device according to claim 8 in which the assembly of outer disks of (c) and guide means of (d) are inserted within the orifices of the supporting structure of (a) without the interposition of the tubular housing of (b).
10. A preforming device for wire linear material comprising:
a. a rotatable shaft,
b. a series of supporting members extending transversely from said shaft,
c. a plurality of pairs of disks rotatably mounted in a pattern upon adjacent supporting members,
d. each disk having a groove for guiding linear material past said disks,
e. a plurality of cylindrical guide means having a smaller diameter than said disks and mounted between and connecting each said pair of disks,
f. each disk upon at least one of said supporting members being associated with rotating means arranged to rotate all of said disks simultaneously to the same uniform degree.
11. A preforming device according to claim 10 wherein said rotating means comprises sprocket rings attached to said disks and movably connected by the guide groove.