US3861615A

US3861615A - Coil forming and packaging

Info

Publication number: US3861615A
Application number: US375373A
Authority: US
Inventors: Jr Roger Kinnicutt
Original assignee: Morgan Construction Co
Current assignee: Siemens Industry Inc
Priority date: 1971-04-15
Filing date: 1973-07-02
Publication date: 1975-01-21
Anticipated expiration: 1992-01-21

Abstract

A method and apparatus for coiling an axially moving product length. The apparatus including a laying head operating to form the product length into a series of rings which are deposited on an underlying platform within an annular space defined by an inner cylindrical core element and an outer container structure. The core element is comprised of an inexpensive flexible material and is supported during coil formation by an expandable shaper located by means of a centering pin on the platform. The outer container structure is movable between an operative position surrounding the core element, and an inoperative position permitting lateral removal of the platform and a completed coil formed thereon beneath the laying head. The method encompasses the operation of the apparatus referred to above, and additionally includes a packaging operation, the initial step of which involves replacing the expandable shaper with a multi-sided brace, the corners of which bear against the inside of the core element. The outer surface of the coil is wrapped, again preferably with an inexpensive flexible material, and a plurality of retaining straps are applied to tie the entire package together. The location and number of retaining straps preferably coincides with the location and number of the corners of the multi-sided brace. The invention further encompasses the resulting packaged coil.

Description

United States Patent 1191 Kinnicutt, Jr.

[ COIL FORMING AND PACKAGING [75] Inventor: Roger Kinnicutt, Jr., Worcester,

Mass.

[73] Assignee: Morgan Construction Company,

Worcester, Mass.

22 Filed: July 2,1973

21 Appl. No.: 375,373

Related U.S. Application Data [63] Continuation of Ser. No. 134,179, April 15, 1971,

Primary Examiner-Edward J. McCarthy Attorney, Agent, or Firm-Thompson, Birch, Gauthler & Samuels 1451 Jan. 21, 1975 [57] ABSTRACT A method and apparatus for coiling an axially moving product length. The apparatus including a laying head operating to form the product length into a series of rings which are deposited on an underlying platform within an annular space defined by an inner cylindrical core element and an outer container structure. The core element is comprised of an inexpensive flexible material and is supported during coil formation by an expandable shaper located by means of a centering pin on the platform. The outer container structure is movable between an operative position surrounding the core element, and an inoperative position permitting lateral removal of the platform and a completed coil formed thereon beneath the laying head.

The method encompasses the operation of the apparatus referred to above, and additionally includes a packaging operation, the initial step of which involves replacing the expandable shaper with a multi-sided brace, the corners of which bear against the inside of the core element. The outer surface of the coil is wrapped, again preferably with an inexpensive flexible material, and a plurality of retaining straps are applied to tie the entire package together. The location and number of retaining straps preferably coincides with the location and number of the corners of the multi-sided brace. The invention further encompasses the resulting packaged coil.

PAIENIEU M21 sum 3 or e ATTORNEYS PATENTED JANE l 1375 SHEET- l 0F 6 MN 5E ONP PATENTEU 2 I975 SHEET 6 OF 6 m' wwaaww ATTORNEYS COIL FORMING AND PACKAGING DESCRIPTION OF THE INVENTION This is a continuation of application Ser. No. 134,179 filed on Apr. 15, 1971, abandoned.

This invention relates to an apparatus for coiling an axially moving product length into an annular coil, to the method of forming the aforesaid coil and of packaging the same, and to the resulting packaged coil. The invention is especially useful in the formation of large coils of non-ferrous rod or bar, although it will be appreciated from the following detailed description that other uses are also contemplated.

One of the principal objects of the present invention is to provide an improved method and apparatus for forming and packaging large product coils, such as for example coils of copper or aluminum rod being produced by a rolling mill. Another object of the invention is to substantially reduce the costs involved in packaging large product coils. Cost reductions are achieved by providing a method and apparatus which may be operated by a minimum number of personnel, and also by employing inexpensive readily available packaging materials. Still another object of the present invention is the provision of an improved packaged coil, which because of its inherent strength and stability, is easier to handle and also is capable of being stored on its side, thus permitting further space savings in transport carriers and storage areas.

These and other objects and advantages of the present invention will become more apparent as the description proceeds with the aid of the accompanying drawings wherein;

FIGS. 1A and 1B are sequentially arranged schematic views depicting an apparatus embodying the concepts of the present invention in side elevation;

FIGS. 2A and 2B are plan views of the apparatus shown in FIGS. 1A and 1B;

FIG. 3 is a plan view of the conveyor means and platform elevating means at the coil forming station;

FIG. 4 is a sectional view on an enlarged scale taken along line 44 of FIG. la; and,

FIG. 5 is a perspective view of a fully formed and packaged coil in transit on a conventional fork lift truck.

The description will now proceed with initial attention being focused on the apparatus, after which the method and the resulting packaged coil will be described in greater detail.

Referring initially to FIGS. 1A, 1B, 2A and 2B, there is shown an apparatus which may, for convenience of description, be longitudinally subdivided into a Pallet Preparation Station A, a Coil Forming Station B, and a Coil Packaging Station C. Station A is preferably suitably dimensioned to accommodate two pallets at locations (a and (11 A third pallet 10 is located at station B, and other pallets 10 are shown arranged along station C at locations (0 (c (c and (0 The pallets 10 are each provided with a centrally located circular raised platform 11 and a centering means in the form of a vertically protruding shaft or pin 14. Spacer elements indicated typically at 16 are radially arranged around each centering pin 14 on the upper surface 18 of each pallet. Beginning with Station A at location (a a pallet 10 is shown being prepared for use at station B during a coil forming operation. A flexible core element 20 is first positioned around centering pin 14. Due to its inherent flexibility, it will be understood that without internal radial support, the core element will assume a relaxed non-cylindrical shape such as is typically shown in FIG. 2A, resting on the circular raised platform 11 of the pallet.

A portable assembly 21, the lower section of which comprises a shaping means 22 is employed to radially support and impart a cylindrical shape to the core ele' ment 20. The shaping means 22 includes a central tubular shaft 24 which supports a plurality of linkmounted core expanders 26. When the portable assembly 21 is suspended above the core element 20 as shown in FIG. 1A, the core expanders 26 are collapsed inwardly towards shaft 24. As the assembly is lowered, tubular shaft 24 is axially inserted over centering pin 14. Eventually, the bottom edges of the collapsed core expanders 26 contact the underlying pallet platform 11 and this in turn causes the expanders to spread radially outwardly from shaft 24. When the portable assembly 21 is fully lowered, as shown at location (a the expanders 26 are fully extended, thereby radially contacting and imparting a cylindrical shape to the core element 20. It will be understood that a plurality of assem blies 2l, preferably at least three, are employed with the present invention.

At this point it should be mentioned that each pallet 10 is further provided with a plurality of radially ar ranged stops 28 intersperced between the spacer elements 16. Each stop is preferably radially adjustable in relation to the pallet centering pin 14, and is further provided at its outer end with a notch 30, the purpose of which-will presently be described.

Each of the portable assemblies 21 further includes a core adapter generally indicated at 32. The core adapted consists of a generally circular cage made up of tubular elements rigidly supported centrally by tubular shaft 24. Each tubular element has a vertical section 34 having upper and

lower ends

34a and 34b (shown at location (a,) in FIG. 1A). When the portable assembly 21 is fully lowered to its operative position, as shown at location (a the lower ends 34b of the tubular elements on the core adapter 32 rest on the upper edge 36 of the core element 20. When thus arranged, both the expanded core element 20 and the adapter 32 have approximately the same outside diameter and in effect, the core adapter provides a vertical extension of the core element.

The coil forming apparatus at station B includes a laying head assembly generally indicated at 38. The laying head assembly has a vertically disposed rotatable tubular shaft 40 supported by bearings 42 carried on a support structure 44. Shaft 40 may be driven in any known conventional manner, as for example by one or more belts 46 extending between a pulley 48 on the shaft 40 and another pulley 50 on the drive shaft of a gear reducer 52, the latter being driven by a variable speed drive motor (not shown).

Although not shown in the accompanying drawings, it will be understood that suitable guide means are employed to direct the product to be coiled into the upper end 56a of a laying pipe 56 which is carried by the shaft 40 for rotation therewith. The laying pipe extends downwardly and axially through shaft 40 as at 56b before curving laterally and outwardly through an opening 58 in the shaft. Thereafter, the laying pipe takes on a curved configuration as at 56c which extends in a descending somewhat circular path to an exit end d located as shown on the drawings. The lower curved section 560 of the laying pipe is supported at a plurality of points by means of brackets 60 attached to an annular support plate 62 which is in turn secured by additional brackets 64 to the lower end of shaft 40.

As can be best seen in FIG. 4, shaft 40 is further provided at its lower end with a depending shaft extension 66 which is held in place by means of a keeper plate 68. A cylindrical hub 70 is journalled for rotation on shaft extension 66 by means of bearing

assemblies

72a, 72b and 72c. Hub 70 has secured thereto as by welding as at 74 an annular plate 76 which in turn supports a cylindrical stripper drum 78. This construction permits the shaft 40 and the laying pipe 56 supported thereon to rotate freely and independently of the drum 78 in the event that the latter is held stationary by other means.

A roller conveyor 80 extends along the length of the apparatus. The pallets are supported on the conveyor and are moved by any conventional means (not shown) from station to station during operation of the apparatus. Thus, at the completion of each coil forming operation, a loaded pallet is pushed along conveyor 80 from station B to location (0,) at station C and the next prepared pallet is pushed from location (a at Station A to a location underlying the laying head at station B. At this point, with the pallet still supported on roller conveyor 80, there exists a clearance between the core adapter 32 and the stripper drum 78. Elevating means generally indicated at 82 (see FIG. 3) are employed to raise a pallet at the coil forming station B to the position shown in FIGS. 1A and 4. The elevating means in cludes a plurality of screw jacks 84 which are interconnected by intermediate drive shafts and driven by a common drive motor 86. Two of the screw jacks at oppositely disposed corners of the pallet preferably are provided with conical noses 84a which impart a centering action to the pallet which the noses enter vertical receiving passages 85. This in turn assures that the centering pin 14 on the pallet is aligned axially with the rotational axis of the laying pipe 56 when the pallet is raised to its operative position as shown in the drawings. The screw jacks are operated to raise the pallet until the upper ends 34a of the vertical sections 34 on the core adapter 32 contact the lower edge of the stripper drum 78 as at 88. At this point, it should be observed that the stripper drum 78, core adapter 32 and core element 20 each have approximately the same external diameter, thus cooperating to provide a substantially continuous guide surface for the product rings being formed by the rotating laying pipe 56 during the coil forming operation.

Following elevation of the pallet 10 to its operative position at the coil forming station B, as is best shown in FIGS. 2A, and 4, means should preferably be provided to contain and define the outside diameter of the coil about to be formed. To this end, container means generally indicated in FIGS. 2A and 4 at 90 are provided on opposite sides of the roller conveyor 80. In the embodiment herein disclosed, each container means is powered by a double acting cylinder assembly 92 which may be either hydraulically or pneumatically actuated. The piston rod 94 of each cylinder assembly 90 is connected to a vertical container post 96. Other laterally located container posts 96 are likewise connected to each of the piston rods 94 by linkage assemblies generally indicated at 98. When the piston rods 94 are advanced to the position shown by solid lines in the drawings, the container posts 96 and 96 are arranged at circumferentially spaced locations around and spaced radially from the core element 20. When thus positioned, the bottom ends of the container posts 96 and 96' are seated in the notches 30 of the stops 28 on the pallet 10. Thus, the stops 28 limit the inward radial movement of the container posts 96 and 96'. By adjusting the radial positions of the stops 28 in relation to the center of the pallet, the wall thickness of the coil being formed may be varied by the adjustments which correspondingly are made to the radial positions of the container posts 96 and 96 during the operative positioning thereof. When the piston rods 94 are retracted. the container posts 96 and 96' are automatically moved to the inoperative positions shown by dotted lines in FIG. 2A, thus permitting lateral removal of the pallet 10 and a fully formed coil supported thereon from beneath the laying head.

With the apparatus at the coil forming station 8 operatively arranged as shown in FIGS. IA, 2A and 4, the coil forming operation may be initiated. This is accomplished by directing an axially moving product length P, for example copper or aluminum bar, downwardly into the rotating laying pipe 56. The rotating laying pipe forms the product into a succession of rings which descend under the influence of gravity and accumulate in coil form as at 99 on the spacer elements 16 of the underlying pallet 10. The inner diameter of the coil thus formed is defined by the radially expanded core element 20, and the outside diameter of the coil is likewise governed by the operatively positioned container posts 96 and 96'. The coil forming operation will continue until a given product length has been formed into a coil of appropriate size and weight, at which point the container posts 96 and 96' will be returned to their inoperative positions and the elevating means 82 operated to drop the fully loaded pallet 10 back onto the roller conveyor 80. Thereafter, the load pallet will be laterally removed along roller conveyor to location (0 of the coil packaging station C and another fresh pallet will be operatively positioned at the coil forming station in preparation for the next successive coil forming operation. At location (0 a boom assembly generally indicated at 100 is employed to remove the portable assembly 21 from the completed coil. Boom assembly 100 includes a horizontally extending arm 102 which is suitably mounted at one end as at 104 for pivotal movement about a vertical axis 106. A cylinder assembly 108 is mounted to the underside of arm 102. The piston rod 110 of cylinder assembly 108 is attached as at 112 to a cable 114, the other end of which is provided with a hook or other suitable means for connection with a lifting eye 116 on the upper end of the tubular shaft 24 extending centrally through the portable assembly 21. Extension of piston rod 110 will result in a lowering of assembly 21 and conversely retraction of the piston rod will produce a hoisting effect. After an assembly 21 has been hoisted out of a completed coil at location (0 boom assembly 100 is rotated about axis 106 to the position shown in dotted at 100' in FIGS. 1A and 2A, at which point the same assembly 21 will be lowered into another core element at location (a as previously described. The fully loaded pallet 10 at location (q) is now ready for movement along roller conveyor 80 through the remainder of the packaging steps, a description of which will hereinafter be provided in connection with an overall description of the method of the present invention.

The method of the present invention begins with the preparation of a pallet at station A. This includes the removable mounting on the pallet of an upstanding flexible core element 20 which is radially supported and maintained in a cylindrical configuration by shaping means 22 included as part of the portable assembly 21. When thus positioned and radially supported, the bottom edge of the core element 20 is vertically spaced from the upper pallet surface 18 on the spacer elements 16. Preferably, the assembly 21 also includes a core adapted 32 which is mounted on the core element 20 to serve as a vertical extension thereof. A fully prepared pallet is shown at location (a prior to being moved along roller conveyor 80 to the coil forming station.

The coil forming operation at station B has already been reviewed in connection with the description of the apparatus. Likewise, the subsequent removal of the portable assembly 21 from a completed coil on a pallet location at location (c has also been described. Once this has been accomplished, the fully loaded pallet is moved further along conveyor 80 to location (6 at which point a multi-sided brace generally indicated at 118 is axially inserted into the coil. Preferably, brace 118 is triangular in shape with three sides 1 18a meeting at three corners 118b, the latter contacting and lending radial support to the core element 20. While at location (0 the coil is also exteriorly wrapped with a flexible covering 120, for example heavy paper or cardboard. At this point it should be noted that exterior wrapping or covering 120, the multi-sided brace 118 and the core element 20 each have a height which is somewhat less than the height of the completed coil 99. Thus there remains an upwardly protruding portion of the coil shown generally at 99' (see location c in FIG. 1B). The pallet is next moved along conveyor 80 to location (0 at which point strapping machines 121 conveniently located on either side of the path of coil movement along conveyor 80 are employed to apply tensioned retainer straps 122 to the coil at locations adjacent to the corners 118b of the brace 118.

The tension developed in the retainer straps 122 dur ing the strapping operation axially compacts the coil to a height which is approximately equal to that of the flexible outer covering 120 and the interiorly located brace 118 and core element 20. Positioning of the straps around the coil is of course facilitated by the fact that the coil is spaced vertically from the upper surface 118 of the pallet by the spacer elements 16, the latter being suitably grooved to accommodate insertion of the remaining straps across the underside of the coil. If desired, additional retaining straps 123 may be intersperced between the straps 122 in order to further strengthen the overall package. Also, it may be desirable to insert protective pads 124 between the retaining straps and the top and bottom edges of the coil. Once the packaging operation has been completed, the pallet is shifted to location (c.,), at which point the coil may be turned on its side and carried to another location by any suitable means, such as for example a conventional fork lift truck. The resulting package coil is shown in FIG. 5 supported during transit on the forks 126 of a conventional fork lift truck 128.

In light of the foregoing, it will be understood by those skilled in the art that modifications may be made to the apparatus and method without departing from the spirit and scope of the invention. For example, the number of stations along conveyor may be varied to accommodate a greater or lesser number of pallets. Likewise, the conveyor itself may be modified, for example by changing the direction of pallet movement from station to station in order to permit the entire op eration to be performed in a more confined space. Changes may be made to the pallets, it being however preferable to always provide a centering means on each pallet in order to provide a central guide for the shaper means 22 which forms a part of each portable assembly 21. Changes in the design and operation may also be made to the container means employed to radially contain the coil during the coil forming operation. Again, however, it is preferable that any such container means be removable to an inoperative position permitting lateral removal of a pallet and completed coil from beneath the laying head 38.

As to the method employed to package a particula coil, it will be understood that the packaging steps herein described as being sequentially performed at station 0 to 0 may if desired be performed at a single location to one side of the coil forming station B. These and other changes do not, however, materially depart from the invention as described above.

Some of the more significant advantages to be drived from employing the invention will now be briefly reviewed. it should be noted that each coil is formed around a disposable flexible core element which remains in place both during the coil forming operation and thereafter during the packaging operation. The core element 20 is relatively inexpensive, yet it provides a covering which effectively avoids any possibility of the interior product rings being subsequently soiled, scratched or otherwise damaged. Each core element is radially supported by core expanders on one of several portable assemblies 21 which are axially retracted from the completed coil and replaced by a multi-sided brace 118, the latter again being disposable and fabricated by rather inexpensive material. After the coil forming operation and the insertion of the multi-sided brace, the coil is exteriorly wrapped, again with inexpensive flexible material such as for example heavy paper or cardboard, and finally the entire package is tied together by tensioned restraining straps. The outer covering cooperates with the inner core element 20 to protect the major surfaces of the coil, and all of the packaging elements are tied together in a manner which produces a stable damage resistant package without significantly contributing to the overall cost thereof. This is to be contrasted to more conventional prior art techniques where coils have been formed in prefabricated wooden crates which in addition to being expensive, must be repaired after each use, and replaced after very limited use.

It will now be understood by those skilled in the art that the invention is not limited in application to the handling of product emerging from rolling mills, but in addition or alternatively may be employed in other areas where elongated product lengths are to be coiled and packaged preliminary to being subsequently transported and/or stored.

I claim:

1. Apparatus for coiling an axially moving product length comprising in combination: a laying means at a coil forming station, said laying means having a rotating curved laying pipe through which the product length is directed, the curvature of said laying pipe being such that the product length passing therethrough is formed into a succession of product rings, said laying means being further provided with a cylindrical depending skirt member which is located within the circular path defined by the rotating exit end of said laying pipe, said laying pipe being rotatable independently of said skirt member; conveyor means spaced vertically beneath said laying means, said conveyor means extending horizontally from a preparation station on one side of said coil forming station to a packaging station on the opposite side of said coil forming station; platform means movable along said conveyor means, said platform means having a centering pin extending vertically therefrom, the said pin being aligned axially with the rotational axis of said laying pipe when said platform means is located beneath said laying means at said coil forming station; flexible core means surrounding said centering pin; a removable assembly having a centrally located tubular member axially inserted over said centering pin, said assembly being further provided with shaping means for radially imparting a cylindrical shape to said core means; cylindrical adaptor means extending vertically from the upper edge of said core means, the vertical spacing between said conveyor means and said laying means being such that there exists a space between said adaptor means and said skirt member when said platform means is supported on said conveyor means; elevational means at said coil forming station for raising said platform means above said conveyor means, thereby placing said adaptor means in contact with said skirt member, whereupon during the coil forming operation, the successive rings formed by said rotating laying pipe will descend in a generally helical pattern to accumulate around said core means in coil form on said platform means; and container means for defining the outside diameter of the coil thus being formed, said container means including a plurality of vertical posts movable between operative positions arranged circumferentially around and spaced radially from said core means to inoperative positions permitting lateral removal of said platform means along said conveyor means from said coil forming station to said packaging station following completion of the coil forming operation and return of said platform means to a position supported on said conveyor means.

2. Apparatus for coiling a longitudinally moving product length comprising: laying means spaced vertically above platform means, said laying means having a curved laying pipe for receiving the product length, means for rotating said laying pipe to form the product length into a succession of rings which descend under the influence of gravity to accumulate in coil form on said platform means, said laying means being further provided with a circular guide member located within the circular path travelled by the exit end of said rotatable laying pipe, and circular guide means extending vertically between and in removable engagement at its upper and lower ends respectively with said circular guide member and said platform means, the external diameters of said guide member and said guide means being substantially equal, thereby providing a continuous guide for the rings descending from said laying means towards said platform means, the said guide means serving additionally as a circular core about which the rings accumulate on said platform means.

3. The apparatus as claimed in claim 2 further characterized by centering means fixed relative to and protruding vertically from said platform means, and means centrally located at the lower end of said guide means for axially receiving said centering means.

4. The apparatus as claimed in claim 2 wherein the lower end of said guide means includes a plurality of link-mounted elements which are normally collapsed and which are radially expandable upon engagement with said platform means. I

5. The apparatus as claimed in claim 4 further characterized by a flexible core element surrounding said link-mounted elements, the radial expansion of said elements upon engagement with said platform means being operative to impart a cylindrical shape to said core element.

6. The apparatus as claimed in claim 2 further characterized by conveyor means underlying and spaced vertically beneath said laying means, said conveyor means being adapted to transport said platform means into and out of a position underlying said laying means.

7. The apparatus as claimed in claim 6 wherein the combined height of said circular guide means and said platform means is less than the vertical distance be tween said laying means and said conveyor means, and wherein elevating means are provided for raising said platform means above said conveyor to place the upper end of said circular guide means in engagement with said circular guide member.

8. Apparatus for coiling a longitudinally moving product length, comprising: laying means having a curved laying pipe for receiving the product length, means for rotating the laying pipe to form the product length into a succession of rings which descend therefrom under the influence of gravity, said laying means being further provided with a circular guide member located within the circular path travelled by the exit end of said laying pipe; conveyor means spaced vertically beneath and extending horizontally in relation to said laying means; platform means movable along said conveyor means to a position underlying said laying means; circular guide means removably mounted on and extending vertically from said platform means, the combined height of said platform means and said circular guide means being less than the vertical distance be tween said conveyor means and said laying means; and elevating means for raising said platform means above said conveyor means to place the upper end of said circular guide means in engagement with said circular guide member, the external diameters of said guide member and said guide means being substantially equal, thereby providing a continuous guide for the rings descending from said laying means to accumulate in coil form on said platform means.

Claims

4. The apparatus as claimed in claim 2 wherein the lower end of said guide means includes a plurality of link-mounted elements which are normally collapsed and which are radially expandable upon engagement with said platform means.

7. The apparatus as claimed in claim 6 wherein the combined height of said circular guide means and said platform means is less than the vertical distance between said laying means and said conveyor means, and wherein elevating means are provided for raising said platform means above said conveyor to place the upper end of said circular guide means in engagement with said circular guide member.

8. Apparatus for coiling a longitudinally moving product length, comprising: laying means having a curved laying pipe for receiving the product length, means for rotating the laying pipe to form the product length into a succession of rings which descend therefrom under the influence of gravity, said laying means being further provided with a circular guide member located within the circular path travelled by the exit end of said laying pipe; conveyor means spaced vertically beneath and extending horizontally in relation to said laying means; platform means movable along said conveyor means to a position underlying said laying means; circular guide means removably mounted on and extending vertically from said platform means, the combined height of said platform means and said circular guide means being less than the vertical distance between said conveyor means and said laying means; and elevating means for raising said platform means above said conveyor means to place the upper end of said circular guide means in engagement with said circular guide member, the external diameters of said guide member and said guide means being substantially equal, thereby providing a continuous guide for the rings descending from said laying means to accumulate in coil form on said platform means.