US3881236A - Method of providing ball ends on guitar strings - Google Patents
Method of providing ball ends on guitar strings Download PDFInfo
- Publication number
- US3881236A US3881236A US373950A US37395073A US3881236A US 3881236 A US3881236 A US 3881236A US 373950 A US373950 A US 373950A US 37395073 A US37395073 A US 37395073A US 3881236 A US3881236 A US 3881236A
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- United States
- Prior art keywords
- string
- end portion
- ferrule
- tube
- metal
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- G—PHYSICS
- G10—MUSICAL INSTRUMENTS; ACOUSTICS
- G10D—STRINGED MUSICAL INSTRUMENTS; WIND MUSICAL INSTRUMENTS; ACCORDIONS OR CONCERTINAS; PERCUSSION MUSICAL INSTRUMENTS; AEOLIAN HARPS; SINGING-FLAME MUSICAL INSTRUMENTS; MUSICAL INSTRUMENTS NOT OTHERWISE PROVIDED FOR
- G10D3/00—Details of, or accessories for, stringed musical instruments, e.g. slide-bars
- G10D3/10—Strings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4957—Sound device making
- Y10T29/49574—Musical instrument or tuning fork making
Definitions
- ABSTRACT The method comprises providing the end of a guitar string in a metal ferrule, exerting lateral compressive forces on opposite sides of the ferrule and at longitudinally-spaced points therealong in order to grip spaced portions of the string and also cause lateral offsetting of such string portions from each other, and thereafter exerting longitudinal compressive forces on the ferrule to effect tight folding and cold flow of the metal and to cause the string end to assume an S-shape.
- the resulting article is an S-shaped string end which is embedded in a tightly-folded mass of metal, the metal having axially-spaced lateral fold planes on opposite sides of the bent regions of the string,
- the apparatus comprises two laterally-adjacent chambers each adapted to hold a metal ferrule, one of such chambers being associated with a means to apply lateral compressive forces, the other of such chambers being associated with a means to apply longitudinal compressive forces.
- the end of a guitar string is inserted into the ferrule in the one chamber, being pinched and held in such ferrule as the result of application of the lateral compressive forces. Be cause the string end is thus held in the ferrule. the string end moves with the ferrule to the other chamber in which longitudinal compression occurs to effect controlled folding of the ferrule.
- the ferrules are mounted on a feed belt which is actuated by a feeding device, and are sheared off the belt as the result of the longitudinal compression.
- the invention relates to the field of providing enlarged end portions on guitar strings, both wrapped strings and bare or unwrapped strings.
- the enlarged end portions may for convenience be referred to as ball ends, but this does not denote sphericity or even roundness.
- each string of an electric guitar or similar musical instrument is normally provided with an enlarging means which prevents such end from being drawn through a hole in an anchoring means near the tail of the instrument.
- the end not enlarged is first threaded through the hole and is then connected to the tuning screw or peg, so that turning of the tuning screw tensions the string.
- the enlargement of the one end is effected by manually looping such end around a metal eyelet having an external annular groove therein, and then manually twisting the end upon an adjacent por tion of the string in order to lock the eyelet in place. If the string is one which is to be wrapped, the wrapping is thereafter provided on the string.
- a major problem relates to the provision of an appartus wherein at least two operations (namely, lateral and longitudinal compression) are performed simultaneously, so that a high rate of production is achieved.
- the second (additional) embodiment of the present apparatus achieves such simultaneous performance of two operations, by effectively gripping the string end in a ferrule at a first location, and then automatically shifting the ferrule and gripped string end to a second location where longitudinal compression is effected. Because the string is long, springy, etc., it is surprising that the string portion adjacent the laterally-compressed ferrule may be accurately and automatically located in the port adjacent the longitudinal compression chamber.
- the end of a metal guitar string is provided longitudinally within a metal ferrule or tube, and lateral compressive forces are applied externally to the ferrule to deform the same, Longitudinal compressive forces are then applied to the ferrulee while it is confined within a forming chamber.
- the longitudinal forces are such that the ferrule metal cold flows to substantially fill the forming chamber and to surround and grip the string end for prevention of withdrawal thereof.
- the lateral compressive forces are applied by staking longitudinally spaced points along the ferrule and on opposite sides thereof.
- the ferrule is thus deformed in a controlled manner ef fecting pinching of one string portion against one side of the ferrule, and of another string portion against the opposite side of the ferrule.
- the string is accordingly gripped in the ferrule in a manner causing the string end to be S-shaped (generally sinusoidal) after the longitudinal compressive forces have been applied to achieve controlled folding of the ferrule.
- the resulting article comprises the combination of a guitar string with a ball end, the string portion in the ball end being S-shaped, the ball end having lateral fold planes on opposite sides thereof.
- Additional features of the method include providing notches on the ferrule end and causing the teeth between such notches to cam into the string to grip the same.
- a neck is extruded adjacent the main body of the ball end, not only to further grip the string but also to permit a single set of dies to operate on strings of different diameters.
- the forces, particularly the longitudinal forces, are hydraulically created and result in variable strokes, as required by factors including string diameter.
- the two chambers are defined in a die apparatus which, while it is closed, permits lateral deformation of the ferrule in one chamber, and longitudinal deformation and controlled folding of the ferrule in the other. After the dies open, the laterally-deformed ferrule is shifted from the one chamber to the other, and carries with it the end of the guitar string to be ball-ended.
- Such shifting from one chamber to the other is effected automatically by a feeding and guide means for a feed strip to which are connected a large number of ferrules.
- FIG. I is an exploded isometric view schematically illustrating a first embodiment of die and cylinder apparatus for performing the present method, a showing of the lower staking mechanism being omitted;
- FIG. 2 is an enlarged longitudinal sectional view schematically representing the dies in closed condition and prior to performance of the staking (lateral deformation) step;
- FIG. 3 is a further enlarged view corresponding to the central portion of FIG. 2 but showing the conditions of the elements upon completion of the staking operation;
- FIG. 4 is a corresponding view illustrating the commencement of the longitudinal deformation (compression) step
- FIG. 5 illustrates the positions of the parts at the completion of the longitudinal deformation (compression) step
- FIG. 5a is an enlarged view showing the ball-end of FIG. 5;
- FIG. 6 is an isometric view showing the string end disposed in the ferrule prior to any deformation
- FIG. 6a is a transverse sectional view on line 6a-6a of FIG. 6;
- FIG. 7 is a view corresponding to FIG. 6 but showing the parts after completion of the staking step
- FIG. 8 shows the conditions of the parts after the initial portion of the longitudinal compression step
- FIG. 9 illustrates the parts after completion of the longitudinal compression step
- FIGS. l0l2, inclusive correspond respectively to FIGS. 35, inclusive, but illustrate the provision of a ball end on a relatively small-diameter bare or unwrapped string;
- FIG. 13 is generally similar to FIG. I, but showing a second embodiment of the apparatus
- FIGS. 14 and 140 are enlarged vertical sectional views taken longitudinally of the feed strip (tape or belt) for the ferrules, as viewed in a direction from lower-left to upper-right in FIG. I3, and showing the dies in both open and closed positions;
- FIG. 15 is another vertical sectional view, but taken forwardly of the feed strip, and showing the dies in closed condition;
- FIG. 16 is an enlarged vertical sectional view taken longitudinally of the staking (lateral deformation) chamber, showing the condition of the parts prior to operation of the staking pins;
- FIG. 17 corresponds to FIG. 16 but shows the condition of the parts after operation of the staking pins
- FIG. 18 is an enlarged vertical sectional view taken longitudinally of the longitudinal compression or folding chamber, and illustrating the operation of the ram not only to effect longitudinal compression and thus controlled folding of the ferrule, but also to effect shearing-off of the ferrule from the feed strip;
- FIG. 19 is a greatly enlarged isometric view generally corresponding to the lower-central region of FIG. 13;
- FIG. 20 is an enlarged isometric view of a section of the tape having ferrules or tubes thereon.
- guitar string as used herein contemplate not only strings for guitars but also for related musical instruments, such as banjos, mandolins, electric basses,
- the first embodiment of the apparatus for performing the present method may comprise an upper die 10 having downwardlyextending guide posts I] thereon, and a lower die 12 having bores 13 respectively adapted to receive the guide posts II.
- An upper stake pin 14 and helical retraction spring 15 are mounted in a bore (and a counterbore) in upper die 10, the stake pin being adapted to be forced downwardly by a hydraulic cylinder I6.
- a lower stake pin I7 and spring I8 are mounted in a bore (and counterbore) in the lower die 12, and a second hydraulic cylinder 19 is provided to force such lower stake pin upwardly.
- the bore (and counterbore) for elements 14-15 is numbered 21
- the bore (and counterbore) for elements 17-18 is numbered 22.
- Bore 21 is offset from bore 22 in order that the stake pins 14 and I7 will operate upon opposite sides of a metal ferrule or tube 23 at longitudinally-spaced regions therealong.
- the cylinders I6 and 19 are connected, respectively, to dies 10 and 12 by suitable means. for example by screws (not shown) adapted to be projected through openings indicated at 24 and 25 in FIG. I.
- upper and lower dies 10 and 12 have formed therein corresponding semicylindrical chambers adapted to form a cylindrical die cavity or forming chamber 26 when the dies are in the closed condition illustrated in various views other than FIG. I.
- Cavity 26 communicates coaxially, when the dies are in closed condition, with an elongated wire or string port 27 which, in turn, communicates coaxially with a divergent or conical mouth 28 as best shown in FIGS. I and 2. It is to be understood that, like the die cavity 26, the port and mouth 27 and 28 are each formed half by upper die 10 and half by lower die 12.
- die cavity 26 is generally hemispherical.
- the cavity walls at such end thus formed rounded cam surfaces 29 (FIG. 3) which converge toward wire port 27.
- the cavity walls at such end may be termed a closure.
- the portion of the die cavity remote from cam surfaces 29 receives coaxially a cylindrical ram 31 having a dished or concave end surface 32.
- the ram 31 connects coaxially to a piston 33 of larger diameter, such piston being disposed slidably in a piston chamber 34 half of which is defined by upper die and the other half of which is defined by lower die 12.
- piston 33 connects through a pivot connection 36 with the piston portion of a hydraulic cylinder 37 which is suitably supported by means, not shown.
- the bores 21 and 22, and associated stake pins 14 and 17, are spaced sufficient distances from cam surfaces 29 that the entire ferrule 23 may be shifted for wardly (to the left) and away from the stake pins during the latter portions of the forming operation.
- the stake pins are shown as having cylindrical inner end portions the tips of which are hemispherical, such cylindrical portions projecting through upper and lower ports indicated at 38 and 39.
- the stake pins are sufficiently close to each other, in a direction longitudinally of the ferrule or tube, that the staking will occur at regions which are respectively spaced from the ends of the ferrule.
- the cylindrical inner end portions of the stake pins, which engage ferrule or tube 23, have diameters much smaller than the diameter of the ferrule. However, the diameters of such inner end portions are sufficiently large to assure that the string will be properly gripped and flexed, in response to the staking operation, as set forth below.
- Suitable means are provided to open and close the dies 10, 12, and to mount the various elements in proper relationship.
- FIGS. 1-9, inclusive the method is illustrated relative to the ball-ending of a pre-wrapped string for a guitar or the like. Relative to FIGS. 10-12, the method is illustrated relative to a small-diameter bare or unwrapped string. It is to be understood that the method may also be performed relative to numerous intermediate and other sizes and types of strings for musical instruments.
- the wrapped string is indicated by the reference numeral 41. It comprises a core wire 42 (FIGS. 6-9) of high tensile strength metal such as steel and which is relatively stiff and springy. Around such core 42 is wrapped, in tightly-wound helical relationship, a wrap wire 43 of a softer metal such as nickel or bronze. The core may also be double-wrapped, there being two wrap wire instead of one.
- a core wire 42 (FIGS. 6-9) of high tensile strength metal such as steel and which is relatively stiff and springy.
- a wrap wire 43 of a softer metal such as nickel or bronze.
- the core may also be double-wrapped, there being two wrap wire instead of one.
- the outer diameter of the string 41 (that is to say, of the helical wrap thereon) is slightly smaller than the diameter of the wire (string) port 27 whereby the string will not be a tight fit in such port.
- the inner end of string 41 is disposed longitudinally within the elongated ferrule 23. This may be done by positioning the ferrule 23 in die cavity 26 by first opening and then closing the dies l0, l2. Ferrule 23 is positioned adjacent the inner end 32 of ram 3! (when such ram is in the predetermined retracted position shown in FIGS. 2 and 3), and also adjacent the ports 38-39 for staking pins 14 and 17. The string 41 is then inserted into mouth 28 and through port 27 and through cavity or chamber 26 into the ferrule 23, until the string end engages the dished end 32 of ram 3] as shown in FIG. 2. The inserted string is also shown in FIG. 6.
- Ferrule 23 is a tube formed of a relatively hard metal but one which is capable of deformation and cold flow when very high pressures are applied as stated below.
- the tube has a length much larger than its outer diameter, for example, between two and three times its outer diameter. As indicated above, the tube length is such that the staking takes place at regions spaced inwardly from the extreme ends of the tube.
- the outer diameter of the ferrule or tube 23 is only slightly smaller than the diameter of cavity 26, so that the ferrule is a sliding fit in such cavity.
- the inner diameter of the ferrule is much larger than the outer diameter of the string.
- the inner diameter of the ferrule may range from about twice the outer diameter of the string (including any wrapping thereon) to many times the diameter of the string (in the case of small-diameter strings). Because the inner diameter of the tube is thus much larger than the string diameter, the string may assume a generally S-shaped configuration in the tube.
- the next step in the method comprises applying lateral compressive or deforming forces to the ferrule in order to deform the same. Because of the offsetting of the staking pins 14 and 17 (longitudinally of the tube or ferrule) as described above, the lateral compressive forces are applied at longitudinallyspaced points along the ferrule and on diametricallyopposite sides thereof. (In its broader aspects, the present method also comprises inserting the string end after lateral deformation of the ferrule has been at least partially completed.)
- the upper hydraulic cylinder ]6 is employed to force staking pin 14 downwardly, against the bias of spring 15, until the rounded lower end of the staking pin deforms the upper wall of ferrule 23 into pressure contact with the guitar string 41, such string then being gripped or pinched (FIG. 3) between the deformed upper wall of the ferrule and an undeformed portion of the lower wall thereof.
- the lower cylinder 19 is employed to force the lower staking pin 17 upwardly to deform the lower wall of the ferrule 23 and cause the same to grip or pinch the adjacent string portion between the deformed lower wall and an undeformed part of the upper wall. Because the described staking is done in a chamber the side walls of which are closely adjacent the ferrule, such staking does not effect collapse or squashing of the entire ferrule.
- the result of the staking operation is, as illustrated in FIG. 3, a relationship whereby the string is gripped or pinched at two points and, furthermore, the string regions are laterally offset relative to each other.
- the inwardly-deformed portions of the ferrule wall, and which receive the staking pins 14 and 17, are respec tively numbered 45 and 46.
- the staked ferrule is addi tionally shown in FIG. 7.
- the inwardlydeformed parts 45 and 46 are collapsed to result in longitudinally-offset radially-extending fold planes 51 and 52, FIGS. 5, a and 9, each such plane extending outwardly from one of the bends in the S.
- the S-shaped string portion which is disposed within the resulting ball end is given the reference numeral 53 in FIGS. 5 and 5a.
- the finished ball end is denoted 54 in FIGS. 5, 5a and 9.
- the tube or ferrule is thus tightly folded in a controlled, predetermined manner which makes possible the mass manufacture of ball-ended strings having substantially uniform high-strength characteristics.
- Such folding effects bending, or additional bending, of the string end.
- the staking or lateral deformation step prepares or preconditions the tube so that the longitudinal deformation step will achieve predetermined folding thereof.
- the lateral deformation step is preferably also such that the string end is pinched and thus retained in the tube. Therefore, the string end is not separated from the tube either during shifting of the ferrule from its lateral deformation station to its longitudinal deformation station, or during the actual performance of the longitudinal deformation and folding step.
- the combined volumes of the tube and of the string end are much less than the volume of the forming chamber or cavity. Therefore, large voids are present in the chamber or cavity, the word large" being employed in its relative sense instead of its absolute sense because the entire forming chamber or cavity is actually small.
- the tube is caused to flow until the voids are substantially eliminated. Such flow is effected by moving ram 31 to progressively reduce the size of the forming chamber or cavity.
- the hydraulic pressure is preferably applied to cylinder 37 for a time period sufficiently long to insure that there will be no substantial spring back of the metal with consequent loosening of the grip on the S-shaped portion 53 of the string 41 (FIGS. 5 and 5a).
- the time required to shift ram 31 from the FIG. 4 position to the FIG. 5 position may be, for example, a little under l second, including the hold" which occurs before the ram 31 is retracted.
- Such article comprises a string, including a core wire and a wrap wire, which has an S-shaped end portion disposed within a tightlyfolded and compressed mass of metal, such mass having radial fold planes (5] and 52) adjacent the bends in the S and on opposite sides of the ball end.
- the embedded string end portion is shaped generally as a single full cycle of a sine wave.
- the embedded string end portion is bent in two places, at B and C in FIG. 50, each such bend being either the crest or trough of the sine wave (depending upon whether the string end portion is positioned as shown in FIG. 5a, or is inverted).
- One of the fold planes, number 51 is directly opposite the bend 8
- the other fold plane, number 52 is directly opposite bend C.
- the inner region of each fold plane 51 and 52 is generally between adjacent portions of the sine wave or S" (that is to say, the inner portion of plane 51 is in the trough above bend B, whereas the inner portion of plane 52 is in the crest below bend C).
- each fold plane 51 and 52 is transverse (preferably, generally perpendicular) to the portion of string 41 which is adjacent the mass of folded metal but is not embedded therein. Such adjacent string portion is indicated at P in FIG. 50. It is also to be noted that the fold planes S1 and 52 are substantially parallel to each other, and spaced from each other. The word plane is not employed in a precise sense, but only a general sense, since the folds may actually be somewhat irregular.
- the portion P, FIG. 5a, lies between two lines L and L which are respectively tangential to bends C and B in the S-shaped embedded string end portion.
- the mass of tightly-folded metal conforms to the shape of the outer (left) end portion of the die cavity or chamber 26, the mass has a cylindrical outer surface generally coaxial with the string portion P (FIG. Also, one end of the cylindrical mass is generally hemispherical (corresponding to cam surfaces 29), whereas the other end of the cylindrical mass is convex (corresponding to dished end 32 of ram 31). There is a neck 49 around the string at the small portion of the generally hemispherical end.
- each bend in the guitar string is smooth, not sharp, since a sharp bend in the string may cause a point of weakness.
- the method is illustrated as employed in ball-ending a small-diameter unwrapped string 56 formed of music wire, a relatively springy steel. Such music wire is coated with tin or other corrosion-resistant metal.
- the end of the wire is disposed longitudinally within the ferrule 23 as described relative to FIG. 2 of the previous embodiment.
- hydraulic cylinders 16 and 19 are supplied with hydraulic fluid under pressure to cause radial'inward shifting of staking pins 14 and 17 until such pins move inwardly as far as they can go, namely until spaced portions of string 56 are pinched against opposite wall portions of the ferrule 23 as shown in FIG. 10.
- the resulting inwardly-deformed portions of the ferrule wall are much deeper in FIG. 10 than is shown relative to FIG. 3.
- the string portions are pinched and gripped by the inward protuberances 57 and 58, whereby the string is prevented from shifting axially relative to the ferrule during the subsequent longitudinal compression step.
- longitudinally-spaced portions of the string are laterally offset relative to each other.
- Additional leftward shifting of ram 31 then causes cold flow of the ferrule metal to fill in the voids or gaps, to form the fold planes 59 and 60, and to create the neck 61.
- neck 6 Because of the relatively small diameter of the string 56, neck 6] is substantially thicker than that shown in FIG. relative to neck 49.
- the planes 59 and 60 are deeper in FIG. 12 than in FIGS. 5 and 5a, because of the deeper elements 57 and 58 (FIG.
- the article resulting from the embodiment of FIGS. l0-] 2 is generally the same as the previously-described article, except that the string is smaller in diameter and is not wrapped, and except that the neck 61 is larger and the body of the ball end is shorter.
- the ferrule 23 is formed of sheet metal which is bent into cylindrical shape whereby a longitudinal seam (which need not be soldered or otherwise fused or ioincd) is provided at 62 (FIG. 6a). Seam 62 is an unfused, longitudinal butt seam. It is a feature of the invention that the lower staking pin may operate on the seamed portion of the ferrule 23.
- the diameter of the ferrule 23 is such that it is (as stated above) a sliding fit in the die cavity 26.
- the outer diameter of the ferrule is 0. I56 inch, whereas the inner diameter is 0.114 inch.
- the length of the ferrule, including teeth 48, is 0.375 inch.
- the pressure of the fluid introduced into cylinder 37 is such that a compressive force of 157,000 pounds per square inch is applied to the ferrule in a longitudinal direction in order to compress the same from the FIG. 11 position to the FIG. 12 position (or from the FIG. 4 position to the FIG. 5 position).
- the pressure of the hydraulic fluid introduced into staking cylinders 16 and 19 is such that the pressure at the inner end of each staking pin is 56,600 pounds per square inch.
- the sheet metal forming the ferrule 23 is caused to be relatively hard in order to provide an effective grip on the wire therein, particularly on the small-diameter wires which tend to pull out unless very firmly gripped.
- An exemplary metal is tin-coated rolled sheet steel, the tin providing resistance to corrosion and rusting. More specfically, the tin-coated rolled steel is tin mill, having a Rockwell hardness (30 T scale) of about 62/68, and a Rockwell hardness (B scale) of about 68/77.
- the string size employed with the described ferrule and apparatus may range from about 0.009 inch diameter to about 0.059 inch diameter (including the wrap). It is to be understood, however, that other diameters may be employed with other ferrules and modified apparatus.
- the ferrule 23 may be formed around the string 41 or 56, instead of being first formed and then the string introduced therein. This may be done at a first station, following which staking by means of pins l4, 17 or their equivalents is effected at a second station, following which the longitudinal forming effected by shifting of ram 31 is effected at a third station.
- the operation may be performed simultaneously (in parallel) on different parts at the different stations, which increases the rate of manufacture.
- the die cavity 26 need not be as long as that shown in the present drawings since it is not then necessary to shift the ferrule 23 away from the staking pins (staking having been performed at another station).
- a lateral deformation step is performed when the ferrule is in one location, following which a longitudinal deformation and folding step is performed when the ferrule is in a different location.
- the lateral deformation (staking) step is performed at one end of die cavity 26, whereas the longitudinal deformation step is performed at the other end of such cavity as shown in FIGS. 4 and 5.
- the ferrule 23 and the string end gripped therein are shifted from the one location to the other.
- such shifting of the ferrule 23 and of the string end gripped therein is in a direction longitudinal to the ferrule (namely, along the die cavity 26).
- FIGS. 13-20 inclusive, a second or additional apparatus embodiment wherein the ferrule and the string end gripped therein are not shifted longitudinally in the same chamber after completion of the lateral deformation (staking) step, but instead are shifted laterally from one chamber to a completely different chamber after completion of such step.
- the apparatus and method of FIGS. 13-20 are such that lateral deforma tion and longitudinal deformation occur simultaneously relative to ferrules in the two chambers or die cavities, thus greatly increasing the rate of production of the ball-ended strings.
- FIGS. 13-20 The embodiment of FIGS.
- 13-20 also incorporates an automatic means for sensing when the end of the guitar string has been fully inserted into a ferrule, and for initiating the cycle of operation in immediate response to such full insertion. It is thus assured that no ball end will be manufactured wherein the string has been only partially inserted. and it is also assured that the maximum speed of production will be achieved.
- FIGS. 13-20 are identical to those described relative to FIGS. 1-12.
- the second embodiment of the apparatus comprises an upper die 66 which mates with a lower die 67, the upper and lower dies being associated with each other by means of posts 68 and bores 69.
- dies 66 and 67 When dies 66 and 67 are in closed condition, touching or substantially touching each other, they define therebetween first and second laterally-spaced die cavities 71 and 72.
- Both die cavities 71 and 72 are cylindrical, and each is adapted to receive snugly a cylindrical tube or ferrule 73.
- the outer end of die cavity 72 is rounded or hemispherical as described relative to cam surfaces 29. FIGS. 3 and 4.
- the first die cavity, number 71 is adapted to hold ferrule 73 during the lateral compression or staking operation
- the second die cavity 72 is adapted to hold the ferrule 73 during the longitudinal compression or folding operation.
- a string end may be inserted into cavity 71, such cavity communicates coaxially with an elongated string post 74 the outer end of which is conical to form a mouth 76.
- Elements 74 and 76 generally correspond to string port 27 and mouth 28 shown in FIGS. 1 and 2.
- the second die cavity 72 in which the longitudinal compression or folding occurs, communicates coaxially with a string port 77 the outer end of which connects with a frustoconical intermediate portion 78.
- Interme diate portion 78 in turn, communicates with a large mouth portion 79 formed in the lower die 67 but not necessarily formed in upper die 66.
- Upper and lower staking means are associated, respectively, with the uper and lower dies 66 and 67 and with the first die cavity 71, in order to effect lateral deformation or compression of the ferrule 73 in such die cavity.
- the staking means correspond substantially to those described above relative to the first embodiment of the invention, and therefore have been given the same reference numerals except followed by the letter a in each instance.
- the upper and lower stake pins 14a and 17a, respectively, are therefore positioned and adapted to penetrate die cavity 71 from diametrically opposite sides thereof and at longitudinally-spaced points therealong.
- the means for effecting longitudinal compression of the tube or ferrule 73 in the second die cavity 72 corresponds generally to that described above relative to FIG. 1.
- a hydraulic cylinder 370 (FIG. 13) is connected by a suitable connector means 81 to a piston 33a and thus to a ram 31a.
- the piston and ram of the present embodiment do not extend between the mated upper and lower dies but instead extend through the lower die only.
- the lower die is preferably maintained stationary at all times, whereas the upper die is moved upwardly and downwardy by suitable actuating means (schematically represented at 94) in order to open and close the dies.
- a multiplicity of tubes or ferrules 73 are formed in equally-spaced locations integrally with a feed belt (strip or tape) 82, as best shown in FIGS. 13 and 20.
- Each ferrule 73 is connected at its rear end by an integral tab 83 (FIGS. 15, 16 and 17) with the forward edge of belt 82.
- Each tab 83 extends downwardly from the forward belt edge to the upper portion of the rear end of each ferrule.
- the ferrules extend perpendicularly away from the belt edge. The unfused seam of each ferrule, which is best shown at 62 in FIG.
- each ferrule is at the lowermost point thereof and lies in a vertical plane which extends through the central portion of the tab 83 for the ferrule.
- the axis of each ferrule lies parallel to, and spaced below, a horizontal plane containing the feed belt 82.
- the spacing between adjacent ferrules 73 on belt 82 is sufficient to provide adequate metal to permit the ferrules to be formed into cylindrical shape. Furthermore, the distance between adjacent ferrules is such that one ferrule may be disposed in the first die cavity 71 at the same time that a second ferrule is disposed in the second die cavity 72, so that operations may be performed simultaneously on the ferrules in the two die cavities.
- Feed belt or strip 82 is fed longitudinally toward dies 66 and 67 by suitable feeding and indexing means represented diagrammatically by the block 84 in FIG. 13.
- the feeding and indexing means 84 includes a suitable pawl and ratchet mechanism which feeds belt 82 forwardly, one step, each time the upper die 66 is fully separated from the lower die 67.
- the distance of forward feeding, during each step corresponds to the distance between the die cavities 71 and 72 (which, in turn, is the same as the distance between adjacent ferrules 73 on feed belt 82).
- the feed belt is provided with spaced circular holes 86 adapted to receive actuating portions of the pawl and ratchet mechanism in the feeding and indexing means 84.
- the feed belt 82 is provided with a longitudinal slot 87 adjacent each tab 83. Each slot 87 results from piercing of belt or strip 82 in order to form a downwardly-extending runner or tab element 88 (which runner extends the full length of each slot 87).
- Feed belt 82 fits into a groove 89 (FIGS. 14 and 19) which is formed beneath the upper and generally horizontal flange 91 of a biasing means 92.
- the biasing means 92 is illustrated to comprise an elongated block which is pivotally mounted (at a pivot means 90, FIGS. 14 and 14a) in the lower die 67 and is adapted to pivot vertically between the position shown in FIG. 14 and that shown in FIG. 14a.
- the biasing means or block 92 is spring-pressed toward the upper position (FIG. 14) by a suitable spring means, such as the one indicated at 93.
- the ferrules 73 rest in a groove 96 which is formed between the dies, as best shown in FIG. 15.
- opening of the dies and consequent lifting of belt 82 causes lifting of the ferrules at least partially out of groove 96, so that the ferrules may be shifted or indexed in response to operation of feed means 84.
- the ferrule in staking cavity 71 is also lifted, and therefore may be fed to cavity 72.
- the biasing means or block 92 terminates adjacent an insulator block 97 formed of a suitable electrical insulating material, such block being fixedly mounted in lower die 67 adjacent the rear (inner) end of staking cavity 71 (FIGS. 16 and 17).
- Insulator block 97 is mounted adjacent a track portion 98 of the lower die 67, which portion 98 extends from a region rearwardly adjacent the die cavity 72 to a region adjacent a discharge port 99 for scrap belt material.
- the upper surfaces of insulator block 97 and of track portion 98 are flush with each other and are substantially horizontal, and are also flush with the upper surface of the main body of biasing block 92 (not flange 91) when the dies are in closed condition (see FIG. 14a).
- the ram 310 passes beneath the upper surface of track portion 98 of the lower die.
- the spacing between the upper region of the ram and the upper surface of track portion 98 is sufficiently small (FIG. 18) that a ferrule 73 may be disposed in die cavity 72 when the dies are in closed condition.
- a suitable track is formed in biasing means 92, in insulator block 97 and in track portion98. in the form of grooves 101-103, respectively. which are in alignment with each other (FIG. 140) when the dies are closed.
- the grooves 101-103 serve as track means for the runner or tab elements 88 (FIGS. 14 and 20) which extend downwardly from feed belt 82, the relationship being such that belt 82 is thus prevented from moving laterally to any substantial extent. Belt 82 and the ferrules thereon are therefore effectively guided into the dies, and it is assured that closing of the dies will cause two adjacent ferrules 73 to be properly located in the two chambers 71 and 72 as desired.
- the biasing block 92 is spring-biased to the upper position, shown in FIG. 14, which causes elevation of tape 82 to lift the ferrules 73 substantially out of groove 96 (at least at the inner end of such groove) and also to lift the staked ferrule out of the lower half of die cavity 71.
- Such meanss 84 then feeds the belt outwardly one step, causing the staked ferrule to be disposed above the lower half of the second die cavity (folding cavity) 72.
- the ferrule immediately to the rear of the staked ferrule is then disposed above the lower half of first die cavity (staking cavity) 71.
- the die actuating means 94 is then operated to shift the upper die element 66 downwardly, which acts on flange 91 to force the biasing means 92 downwardly to the position of FIG. 140. Furthermore, the tape 82 is forced downwardly into engagement with the upper surfaces of the insulator block 97 and of the track portion 98 of the lower die. The resulting downward shifting of tape 82 and of the ferrules 73 thereon causes the staked ferrule and the one immediately adjacent thereto to fit, respectively, into the cavities 72 and 71.
- the present apparatus incorporates a pair of pins (FIGS. 13 and 15) which are mounted on the upper die 66 and are adapted to penetrate holes or bores 106 in the lower die.
- the pins 105 have rounded lower ends, and are adapted to closely straddle one of the ferrules 73 each time the dies close.
- the tape 82 is held in position by flange 91 and by the runners 88 which fit in track groove 101, it follows that downward movement of the pins 105 into straddling relationship with each ferrule will cause straightening of the ferrule relative to tape 82 in the event that the ferrule was not perfectly perpendicular to a vertical plane containing the axis of such tape.
- the integral tabs 83 on the steel tape are adapted to retain permanent sets, so that effect of the described straightening continues after the pins 105 are elevated.
- each ferrule 73 is sheared off automatically from its associated tab 83 in response to the forcing of ram 310 longitudinally into folding chamber 72. This occurs when the leading face of ram 31a moves past an edge 109 (FIG. 18) formed at the inner end of cavity 72. After the ferrule is thus separated from the feed belt 82, the belt is merely scrap. To facilitate disposal of such scrap. and to insure that the belt does not interfere with proper operation of the feeding or other portions of the present ball-ending apparatus, a section of the belt is severed each time the dies 66 and 67 close.
- upper die 66 is provided with a shear member or portion 107 which is adapted to cooperate with a sharp edge member 108 on the lower die, the latter being formed at the end of track portion 98 remote from insulator block 97.
- the shear member 107 moves closely adjacent edge 108 and severs the portion of the tape 82 which extends past such edge I08. The severed scrap then falls through discharge port 99 into a suitable receptacle.
- the present apparatus incorporates an electrical sensing and control means which not only insures that the staking operation (and subsequent operations) will start as soon as the wire end has reached the end of staking chamber 7], but is sufficiently fast acting that there is relatively little time for the operator to pass the string inwardly through an excessive distance, thus causing undesired bending of the string end. Also the operator is prevented from pulling the string outwardly and thus decreasing the anchoring force.
- the sensing and control apparatus comprises the above-mentioned insulating block 97 which is mounted at the inner end of the first or staking cavity 71.
- a rigid conductor 110 mounted in block 97 coaxially of cavity 71 is a rigid conductor 110, for example a brass cylinder.
- the conductor extends through an over-sized bore 111 in lower die 67, and is held coaxially in such bore and in spaced relationship from the walls thereof by means of an insulator 112 shown in FIG. 16.
- the diameter of conductor 110 is at least equal to the diameter of the passage through each ferrule 73. It follows that when a metal guitar string, such as the unwrapped string shown at 56, is inserted through string port 74 and into ferrule 73, the end of the string will engage the end of conductor 110. In extending through the string port 74, the string 56 necessarily engages one of the walls thereof. Therefore, the string comprises an electrical contact means which extends between one of the walls of string port 74 and the end of conductor III). Contact is therefore made as soon as the string end engages the end of conductor I10, and not before.
- a suitable low-voltage power source is connected to the die means, such source having sufficiently low voltage that there is no possible danger to the operator.
- the source is indicated at 113 in FIG. 16, one side of the source connected to lower die 67 and the other side being grounded.
- the voltage of the source may be for example, about 6 to [2 volts.
- the conductor is connected to one side of a suitable relay I I4 (FIG. 16), the other side of the relay being grounded. Therefore, when a string 56 is fully inserted into the ferrule 73 and comes into engagement with conductor 110, a circuit is completed from power source 113 through die 67, thence through the inner end of string 56 to conductor I10, thence through relay 114 to ground, and thence through ground back to the power source H3.
- the resulting energization of relay 114 causes the same to effect immediate initiation of operation of a control circuit indicated schematically at in FIG. 16.
- the control circuit effects immediate operation of cylinders 16a and 19a (FIG. 13) to actuate the staking pins and 17a and effect the staking operation, which causes the ferrule to grip and pinch the inner end of string 56.
- the control circuit also effects operation of ram cylinder 37a to cause the ram 31a to efiect folding and cold flow of the ferrule in chamber 72.
- Control circuit I15 additionally, after both staking and longitudinal compression functions are completed, effects operation of the die actuating means 94 to raise upper die 66, and also operatiton of the strip feeding and indexing means 84 to efiect feeding of the tape and ferrules as soon as the dies are opened, and to effect closing of die 66 onto die 67 as soon as the feeding has been completed.
- the entire cycle is thus automatic and is initiated the instant that the end of string 56 engages conductor 110.
- the cycle includes operation of cylinders 16a and 19a to effect staking in chamber 71, and operation of cylinder 37a to effect folding in chamber 72, these operations occurring simultaneously in order to increase greatly the speed of manufacture. Operation of cylinder 370 also shears a ferrule 73 off of felt 82, as described relative to FIG. 18.
- the upper die 66 is then lifted off the lower, as part of the described automatic cycle of operation, following which the completely ball-ended string drops automatically from the apparatus. as indicated by phantom showings S6-ll7 in FIG. 18. More specifically, the weight of the protruding long operative section of the string 56 causes a pivoting action about the intermediate mouth portion 78, which is followed by a pivoting action about the outer edge of die 67 at the outer end of large mouth 79, after which the ball-ended string drops out of the apparatus.
- the indexing and feeding means 84 is operative to shift the feed belt 82 one step forwardly or to the left (which is part of the above-described automatic cycle of operation). Such shifting is possible, despite the fact that the staked ferrule 73 in cavity 71 is still connected to the tape 82, since the biasing means 92 lifts the tape to the FIG. 14 position, and thus causes elevation of the staked ferrule out of the lower portion (half) of cavity 71.
- the shifting of belt 82 by the indexing and feeding means 84 causes the staked ferrule and, additionally, the gripped string end to shift from a position over the lower half of caity 71 to a position over the lower half of cavity 72 (the latter position being shown in phantom at the upper-left, FIG. 19).
- the string end is held so firmly by the staked ferrule, and the tape 82 is positioned so precisely by the track means 101-403 and by the runner or tab elements 88, that the string end is, after completion of the feeding step, accurately positioned directly above the lower half of string port 77.
- the positioning of the string above the lower half of port 77 must be precise, or else subsequent closing of the dies will not cause the string to be disposed in the port but, instead, to be damaged by the dies. It is also to be notd that the port 77 must be small in diameter in order to prevent excessive extrusion of metal when cylinder 37a is operated. Port 74, to the staking chamber, is also made small in diameter so that the staking operation will cause the gripped string end portion to lie generally in a vertical plane di ametral to ferrule 73 and passing through the usfused seam 62 (FIGS. 60 and 20) and also through tab 83. Such precise positioning of the string end in the staked ferrule contributes to the accurate string positioning above the lower half of port 77.
- actuating means 94 shifts the upper die 66 downwardly to closed position. Because of the above-stated precise string positioning, the end of string 56 then drops into the lower half of port 77, despite the small port diameter. in response to lowering of the staked ferrule into cavity 72. and in response to downward movement of the upper hlf of port 77 (in die 66). Closing of the dies also causes the shear member 107 to cooperate with edge 108 in shearing the portion of belt 82 which is disposed over discharge port 99, causes the pins 105 to 5 align a ferrule 73, and fully defines the two die cavities 71 and 72 and the two string ports 74 and 77. The apparatus is then ready for a new cycle of operation, which commences immediately upon insertion of the string 56 into contact with the electrical conductor 110.
- the apparatus may incorporate a stop 118 (FIG. 13) the upper part of which is adapted to be engaged by the vertical end of connector 81. Stop 118 is so positioned that it is normally not engaged during any part of the opera tional cycle being instead only engaged, in the event of malfunction, in order to prevent damage to the apparatus.
- the ferrules 73 employed in the embodiment of FIGS. 13-20 may be identical to those described in the specific example relative to the first embodiment. However, the teeth at the ferrule ends are truncated as shown clearly in FIG. 20 relative to teeth 48a. The teeth being truncated, notches 47a of FIG. 20 are less deep than are notches 47 of FIGS. 6 and 7.
- the chamber which is referred to is the one present at the end of the forming operation.
- the forming chamber referred to is the one defined between the face of the ram (when such face is at its position closest to string port 27 or 77) and the chamber end (the left end, in FIGS. 5, l2 and 18) opposite such face.
- the tape 82 and ferrules 73 are suitably formed, from sheet metal, at a location different from the location of the illustrated apparatus. It is, however, possible to provide an apparatus wherein the tape 82 and ferrules 73 are formed at additional stations in a single overall machine, which single machine not only forms the tape and ferrules from sheet metal stock, but also incorporates all portions of the apparatus of FIGS. 13-20 and thereore performs all functions of such apparatus. It is also possible, as previously stated, to form the ferrules around the string instead of inserting the string into previously-formed ferrules. Furthermore, it is possible to provide apparatus for effecting automatic feeding of the strings into the staking chamber. If desired, in order to regulate the amount of metal in each neck 49 or 61, inserts may be provided in dies 66 and 67 to define ports 77 having different diameters for use with different diameters of strings.
- a method of providing an enlarged end on a string for a musical instrument which comprises:
- said method further comprises employing as said forming chamber an elongated chamber the diameter of which is only a small amount greater than that of said tube, orienting said tube longitudinally within said forming chamber, and applying said longitudinal compressive forces by forcing a ram longitudinally along said form ing chamber.
- said method further comprises applying said lateral compressive forces to said object in such manner as to pinch at least one region of said string end portion between opposed wall portions of said object.
- a method of providing a ball end on a metal string for a musical instrument which comprises:
- said method further comprises applying said longitudinal compressive force to said tube while said tube is confined in a forming chamber, and causing the magnitude and duration of said longitudinal compressive force to be sufficient to effect cold flow of tube metal around said string end portion, and to cause said tube metal to conform to the shape of at least a substantial part of said string end portion and of said forming chamber.
- said method further comprises applying said transverse compressive force at two longitudinally-spaced regions of said tube and on opposite sides thereof, each of said regions being spaced from the ends of said tube, to thus offset spaced regions of said string end portion, whereby said string end portion assumes an S-shape in response to said longitudinal compressive force.
- a method of ball-ending a metal string for a guitar or the like which comprises:
- said deforming being effected by forcing an object laterally-inwardly against the exterior surface of said tube;
- said method further comprises providing teeth on the end of said tube which is adjacent said string opening, and providing cam surfaces on said wall means around said string opening and shaped to effect radial-inward bending of said teeth into gripping relationship to said string in response to said longitudinal movement of said ram.
- said method further comprises causing said forming chamber to be cylindrical, employing as said tube a ferrule the outer diameter of which is only slightly smaller than the diameter of said forming chamber, and effecting said movement of said ram with sufficient force to effect cold flow of ferrule metal to embed and seize said string end portion and to cause said ferrule metal and the metal of said string end portion to substantially completely fill said chamber between said ram and said string opening.
- a method of ball-ending a metal string for a guitar or the like which comprises:
- said lateral-inward deformation step being performed at longitudinally-spaced points along said tube and on opposite sides thereof, whereby to laterally offset from each other sections of said string end portion;
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Abstract
Description
Claims (81)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US373950A US3881236A (en) | 1972-07-24 | 1973-06-27 | Method of providing ball ends on guitar strings |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US27481072A | 1972-07-24 | 1972-07-24 | |
US373950A US3881236A (en) | 1972-07-24 | 1973-06-27 | Method of providing ball ends on guitar strings |
Publications (1)
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US3881236A true US3881236A (en) | 1975-05-06 |
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ID=26957093
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US373950A Expired - Lifetime US3881236A (en) | 1972-07-24 | 1973-06-27 | Method of providing ball ends on guitar strings |
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US (1) | US3881236A (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4034456A (en) * | 1975-12-11 | 1977-07-12 | Bowers Robert H | Machine for providing ball ends on musical instrument strings |
EP0120363A2 (en) * | 1983-03-28 | 1984-10-03 | Roger H. Siminoff | A string for a musical instrument |
US5913257A (en) * | 1996-05-06 | 1999-06-15 | Fender Musical Instruments Corp. | Method of manufacturing guitar strings, and guitar strings resulting from such method |
US6390320B2 (en) * | 1998-04-29 | 2002-05-21 | Cisco Technology, Inc. | Easily installable and removable electro-magnetic interference shielding faceplate |
US9542915B2 (en) | 2014-12-26 | 2017-01-10 | Mark E. Hackett | Keyless locking tremolo systems and methods |
WO2018212464A1 (en) * | 2017-05-19 | 2018-11-22 | 주식회사 씨엘 | Guitar string and manufacturing method therefor |
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US1507916A (en) * | 1921-05-20 | 1924-09-09 | Frank P Granat | Machine for applying tips to lacings |
US2008227A (en) * | 1933-08-12 | 1935-07-16 | Reilly Frank Ward | Attachement for wire strands |
US2603680A (en) * | 1950-03-01 | 1952-07-15 | Snyder Henry William | Electrical plug connector |
US2869911A (en) * | 1955-05-31 | 1959-01-20 | Wallace J Dickey | Self-locking shackle seal |
US3155136A (en) * | 1960-12-29 | 1964-11-03 | Gen Electric | Apparatus for fabricating wireconnector assemblies |
US3431632A (en) * | 1963-06-17 | 1969-03-11 | Reiner Ind Inc | Method and apparatus for connecting the ends of flexible or resilient strings to tubular elements having closed ends |
US3590140A (en) * | 1970-04-02 | 1971-06-29 | Itt | Cable-insulation-piercing crimp tool, terminal, and method of forming |
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US1507916A (en) * | 1921-05-20 | 1924-09-09 | Frank P Granat | Machine for applying tips to lacings |
US2008227A (en) * | 1933-08-12 | 1935-07-16 | Reilly Frank Ward | Attachement for wire strands |
US2603680A (en) * | 1950-03-01 | 1952-07-15 | Snyder Henry William | Electrical plug connector |
US2869911A (en) * | 1955-05-31 | 1959-01-20 | Wallace J Dickey | Self-locking shackle seal |
US3155136A (en) * | 1960-12-29 | 1964-11-03 | Gen Electric | Apparatus for fabricating wireconnector assemblies |
US3431632A (en) * | 1963-06-17 | 1969-03-11 | Reiner Ind Inc | Method and apparatus for connecting the ends of flexible or resilient strings to tubular elements having closed ends |
US3590140A (en) * | 1970-04-02 | 1971-06-29 | Itt | Cable-insulation-piercing crimp tool, terminal, and method of forming |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4034456A (en) * | 1975-12-11 | 1977-07-12 | Bowers Robert H | Machine for providing ball ends on musical instrument strings |
EP0120363A2 (en) * | 1983-03-28 | 1984-10-03 | Roger H. Siminoff | A string for a musical instrument |
EP0120363A3 (en) * | 1983-03-28 | 1985-05-15 | Roger H. Siminoff | A string for a musical instrument |
US5913257A (en) * | 1996-05-06 | 1999-06-15 | Fender Musical Instruments Corp. | Method of manufacturing guitar strings, and guitar strings resulting from such method |
US6390320B2 (en) * | 1998-04-29 | 2002-05-21 | Cisco Technology, Inc. | Easily installable and removable electro-magnetic interference shielding faceplate |
US9542915B2 (en) | 2014-12-26 | 2017-01-10 | Mark E. Hackett | Keyless locking tremolo systems and methods |
WO2018212464A1 (en) * | 2017-05-19 | 2018-11-22 | 주식회사 씨엘 | Guitar string and manufacturing method therefor |
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