WO2008125965A2 - Method for winding a filiform element into a coil and winding machine implementing said method. - Google Patents

Method for winding a filiform element into a coil and winding machine implementing said method. Download PDF

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Publication number
WO2008125965A2
WO2008125965A2 PCT/IB2008/000913 IB2008000913W WO2008125965A2 WO 2008125965 A2 WO2008125965 A2 WO 2008125965A2 IB 2008000913 W IB2008000913 W IB 2008000913W WO 2008125965 A2 WO2008125965 A2 WO 2008125965A2
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WO
WIPO (PCT)
Prior art keywords
winding
supporting body
filiform element
turns
layer
Prior art date
Application number
PCT/IB2008/000913
Other languages
French (fr)
Other versions
WO2008125965A3 (en
Inventor
Gianfranco Ciuccoli
Original Assignee
C.Z. Elettronica S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by C.Z. Elettronica S.R.L. filed Critical C.Z. Elettronica S.R.L.
Publication of WO2008125965A2 publication Critical patent/WO2008125965A2/en
Publication of WO2008125965A3 publication Critical patent/WO2008125965A3/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H54/00Winding, coiling, or depositing filamentary material
    • B65H54/02Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
    • B65H54/28Traversing devices; Package-shaping arrangements
    • B65H54/2848Arrangements for aligned winding
    • B65H54/2851Arrangements for aligned winding by pressing the material being wound against the drum, flange or already wound material, e.g. by fingers or rollers; guides moved by the already wound material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H55/00Wound packages of filamentary material
    • B65H55/04Wound packages of filamentary material characterised by method of winding

Definitions

  • the present invention concerns a method for winding a filiform element into a coil, particularly suited for use with electric wires, hoses or other filiform elements.
  • the present invention also concerns a winding machine implementing said winding method.
  • the wire is transferred from the above mentioned large coils to smaller reels, where it is wound to form coils having size and weight suitable for the wholesale market.
  • the latter reels are generally made of wood and/or plastic material and are constituted by a substantially cylindrical tubular body provided at its ends with two lateral containment flanges.
  • the winding operation is performed by winding machines, of which several construction variants are known.
  • the machine comprises a frame resting on the ground, associated with a reel and a motor suited to set the reel rotating around its longitudinal axis.
  • the machine also comprises a feeding head, slidingly associated with the frame according to a direction that is parallel to the above mentioned longitudinal axis of the reel, which slidingly supports the wire.
  • the wire is fixed to the reel and, due to the rotation of the latter, is wound around it, guided by the feeding head.
  • Said feeding head moves with alternate motion and constant speed from one side of the reel to the other, in such a way as to displace the wire winding point and wind, on several overlapping layers, substantially helical turns positioned side by side.
  • the machine described above poses a limit to the winding thickness that can be obtained, that is, to the number of turns that can be wound around a given reel.
  • the feeding head guiding the wire is located at a certain distance from the reel. Therefore, the feeding head cannot assure a precise positioning of the wire on the reel.
  • the winding machine comprises a sensor suited to determine the position of the turn being wound, according to which the advance of the feeding head is controlled, moment by moment.
  • This method though preventing the turns from overlapping, has the limitation that it is suitable only for wires with perfectly circular section and almost constant diameter, like for example in the case of welding wires.
  • the present invention aims to overcome all the drawbacks described, which are typical of the winding machines of known type.
  • a filiform element like for example an electric wire
  • the increased length of filiform element wound, with the same coil size makes it possible to reduce the number of coils to be handled in warehouses, thus reducing also the space occupied and the transport costs.
  • the coil has a pleasant appearance.
  • FIG. 1 shows an axonometric view of the winding machine that is the subject of the invention
  • FIG. 1 shows an enlarged detail of Figure 1 ;
  • the filiform element W is wound into a coil 2 around a supporting body 3, which defines a longitudinal axis X and is provided with a lateral flange 3a, 3b at each end.
  • the supporting body 3 is preferably a circular reel, but the method is also suited for use with supporting bodies with non-circular section, for example oval or prismatic section, as in the case of supporting bodies obtained by joining several wooden strips.
  • the filiform element W is preferably an electric wire, even though it may be any item suited to be wound into coils, like for example a hose, a rope, or the like.
  • the filiform element W can clearly have any diameter.
  • one end Wa of the filiform element W is fixed to the surface 4 of the supporting body 3, against a first lateral flange 3a.
  • Fixing is preferably obtained by means of an adhesive tape, even if it can be obtained using other fixing means, or by inserting the filiform element W into a hole made in the supporting body 3, or with another equivalent procedure.
  • the supporting body 3 is then set rotating around its longitudinal axis X in the direction R, in order to wind the filiform element W around the surface of the supporting body itself and thus form a first layer of turns S, Sa, as shown in
  • FIG. 3 which shows a front view of the coil 2.
  • Rotation continues in order to wind up other layers of turns, each one of which overlaps the previous layer, as shown in Figure 9.
  • any number of layers may be wound up and such number will depend, for example, on the diameter d of the filiform element W, as well as on the geometry of the supporting body 3.
  • the predefined displacement distance Z corresponds to the pitch of the turns Sa, where the first length S1 is substantially parallel to the flanges 3a, 3b while the second length S2 defines a deviation angle Ad with respect to the first length S1.
  • each pair of adjacent turns Sa defines, on the surface of the first layer, a depression suitable for housing a corresponding turn of the successive layer, thus allowing a regular winding result to be achieved, according to the object of the invention.
  • the above mentioned predetermined angle can clearly assume any value less than 360°.
  • the value of 300° indicated above ensures the best results in terms of winding regularity, with flexible elements W having various diameters d.
  • N INT(U/d), where U is the usable width of the supporting body 3 while d is the diameter of the filiform element W.
  • the usable width U is defined as the distance D between the lateral flanges 3a, 3b of the supporting body 3, minus half the diameter d of the filiform element W:
  • the predefined displacement distance Z between two adjacent turns Sa is established as the ratio between the usable width U and the predefined number of turns N, according to the formula:
  • the above mentioned arrangement of the turns Sa allows coils 2 to be obtained that have a more orderly aspect than those obtained with the known methods.
  • the filiform element W is kept tensioned for at least one length T adjacent to the coil 2 itself, as shown in Figure 4, which is a top view of the coil 2.
  • the tensioned length T defines, with respect to the reference plane H corresponding to the last turn S wound, an angle of incidence Ai smaller than 90°, on the side corresponding to the advance direction of the layer being wound.
  • the above mentioned angle of incidence Ai is maintained preferably greater than or equal to the deviation angle Ad, so that the filiform element W remains constantly in contact with the guide means 9, to the benefit of winding precision.
  • the tensioned length T of the filiform element W is preferably arranged aligned with the reference plane H of the last turn.
  • the filiform element W overlaps the second-last turn, thus determining the start of the successive layer, as shown in Figure 6.
  • the method requires, at least for the first layer, measurement of the difference in height between the turn S being wound and one or more wound turns Sa, in such a way as to identify the moment at which the above mentioned overlapping takes place.
  • this makes it possible to establish with precision the start of the winding of the first turn of the second layer, in such a way as to be able to synchronize the movement of the tensioned length T with the rotation of the supporting body 3 and correctly adjust the angle of incidence Ai.
  • the tensioned length T can even maintain an angle of incidence Ai equal to zero.
  • variants of the method of the invention may comprise further secondary operations, like for example brushing of the surface of the filiform element W during winding, intended to remove any residues of dirt left from previous processing stages, cutting of the filiform element at the end of winding, continuity test in the case of electric wires, etc.
  • the method described herein is particularly suited to be applied using a winding machine 1 that, as shown in Figure 1 , comprises a frame 1a resting on the ground, with which means 5 for sustaining the supporting body 3 are associated.
  • the machine also comprises driving means 6, preferably an electric motor, for rotating the supporting body 3 around its longitudinal axis X, associated with the sustaining means 5.
  • the winding machine 1 further comprises a head 7 that feeds the filiform element W to the coil 2, said head being slidingly associated with the frame 1a via first sliding means 8 that define a first operating direction L parallel to the longitudinal axis X of the supporting body 3.
  • the first sliding means 8, associated with first actuator means 8a, make it possible to modify the position of the feeding head 7 with respect to the supporting body 3, so that the tensioned length T of the filiform element W remains substantially aligned with the turn S being wound.
  • the feeding head 7 comprises guide means 9 arranged in contact with the filiform element W in proximity to its point P of tangency with the surface 4 of the supporting body 3.
  • the above mentioned guide means 9 allow the tangent point P to be maintained moment by moment in the position required by the method of the invention as described above.
  • the guide means 9 comprise a guide plate 10 where it is possible to identify a surface 10a of contact with the filiform element W that is preferably perpendicular to the surface 4 of the supporting body 3.
  • the guide plate 10 is associated with the feeding head 7 via second sliding means 11 that define a second operating direction L1 perpendicular to the longitudinal axis X of the supporting body 3, in their turn associated with second actuator means not represented herein.
  • the second actuator means 11 allow the guide plate 10 to perform slight movements in the second operating direction L1, so that it can remain in contact with the surface 4 of the supporting body 3 even when this is not cylindrical, following its irregularities.
  • the measurement of the difference in height required by the method of the invention is preferably performed by means of a measuring head 12.
  • This is slidingly associated with the feeding head 7 via third sliding means 13 according to a third operating direction L2 perpendicular to the longitudinal axis X and preferably parallel to the second operating direction L1, along which it is set moving via third actuator means not represented herein.
  • the measuring head 12 comprises at least one first feeler element 14, preferably a disc 14a, positioned in contact with the turn S being wound, and a second feeler element 15, preferably a roller 15a, placed in contact with the previous turns Sa already wound.
  • the first feeler element 14 is slidingly associated with the measuring head 7 according to a sliding direction parallel to the third operating direction L2, in such a way as to be able to move in relation to the second feeler element 15.
  • the feeding head 7 comprises also a wire guide unit 16, operatively connected to the feeding head 7 via connection means 17, with which the filiform element W is slidingly associated.
  • the filiform element W slides between a pair of circular bodies 20,
  • connection means 17 comprise fourth sliding means 18 that slide along a direction parallel to the longitudinal axis X, associated with fourth actuator means not represented herein.
  • the wire guide unit 16 can slide rapidly and independently of the position of the feeding head 7 and of the guide means 9 associated with it.
  • this makes it possible to modify the angle of incidence Ai of the tensioned length T of the filiform element W in relation to the turn S being wound, at the same time maintaining the guide means 9 in the correct position.
  • connection means 17 preferably comprise also fifth sliding means 19 that make the wire guide unit 16 slide along a direction perpendicular to the longitudinal axis X, associated with fifth actuator means not represented herein.
  • Said fifth sliding means 19 allow the tensioned length T to be oriented vertically, as shown in Figures 7 and 8, thus achieving the advantages that are described below.
  • the sliding means 8, 11, 13, 18, 19 mentioned above are linear guides
  • the corresponding actuator means can be, for example, gear motors, hydraulic cylinders, worm screws and/or other equivalent means with which sector technicians are well acquainted.
  • the machine 1 comprises also a control unit, not represented herein, operatively connected to the feeler elements 14, 15, to the driving means 6 and to the actuator means in order to coordinate the movements of the machine 1 during winding.
  • the machine 1 comprises control means, operatively connected to the above mentioned control unit, that allow the operator to set the operating parameters for the winding process, including, for example, the dimensions of the supporting body 3, the diameter of the filiform element W, the number N of turns to be wound, the winding speed, etc.
  • the guide plate 10 remains in contact with the filiform element W so as to define, moment by moment, the point where it is to be laid, that is, the tangent point P.
  • the feeding head 7 is moved and the guide plate 10 is moved with it intermittently along the first operating direction L, with movements corresponding to the above mentioned predefined distance Z.
  • the wire guide unit 16 is constantly maintained in a forward position with respect to the turn S being wound, by operating on the fourth actuator means to maintain the angle of incidence Ai of the tensioned length T of the filiform element W greater than the deviation angle Ad of the turns S, Sa.
  • the tensioned length T is kept horizontal, as shown in Figure 7, to improve the conditions under which the filiform element W is guided.
  • the guide plate 10 is moved away from the supporting body 3 while the measuring head 12 is moved near it, as shown in Figure 5.
  • the tensioned length T of the filiform element W is aligned to the turn S being wound, by moving the wire guide unit 16 parallel to the longitudinal axis X of the supporting body 3.
  • the control unit of the machine 1 can thus synchronize the movement of the feeding head 7 with the beginning of the individual turns.
  • the measuring head 12 is moved away from the supporting body 3 and the feeding head 7 starts moving in the opposite direction, in order to wind up the second layer, as shown in Figure 9.
  • the movement of the feeding head 7 is constant, with the wire guide unit 16 arranged in a slightly forward position with respect to the turn S being wound.
  • the feeding head 7 can move intermittently, analogously to what occurs for the winding of the first layer.
  • the filiform element W spontaneously fits in the depressions between the turns Sa of the previous layer, with no need to be guided by the guide plate 10.
  • the tensioned length T of the filiform element W will be arranged as shown in Figure 8, that is, by reducing curvatures to the minimum, thus allowing the winding speed to be increased.
  • the method of the invention makes it possible to increase the thickness of the winding by up to 20% compared to the known winding methods, increasing by the same percentage also the quantity of filiform element wound.
  • the invention achieves the object of carrying out the winding of a filiform element into a coil that is more regular than allowed by the known methods, even if the filiform element and/or the supporting body present irregularities.

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  • Manufacture Of Motors, Generators (AREA)
  • Coil Winding Methods And Apparatuses (AREA)
  • Linear Motors (AREA)
  • Windings For Motors And Generators (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)

Abstract

The invention is a method for winding a filiform element (W) into a coil (2) on a supporting body (3) defining a longitudinal axis (X), comprising the following operations: fixing one end (Wa) of the filiform element (W) to the surface (4) of the supporting body (3); setting the supporting body (3) rotating around the longitudinal axis (X) to wind a first layer of turns (S, Sa); continuing the rotation to wind other layers of turns (S, Sa). The method comprises also the following operations during winding of each turn (S, Sa) of the first layer: maintaining the tangent point (P) between the filiform element (W) and the surface (4) of the supporting body (3) on a reference plane (H) perpendicular to the longitudinal axis (X) for a predefined angle smaller than 360°; displacing the tangent point (P) of a predefined distance (Z) at right angles to the reference plane (H) during the remaining part of the 360° rotation.

Description

"METHOD FOR WINDING A FILIFORM ELEMENT INTO A COIL AND
WINDING MACHINE IMPLEMENTING SAID METHOD".
DESCRIPTION
The present invention concerns a method for winding a filiform element into a coil, particularly suited for use with electric wires, hoses or other filiform elements.
The present invention also concerns a winding machine implementing said winding method.
It is known that electric wires, in particular those used in industry, are wound around metal reels directly downstream of the wire production process, to form large coils of considerable length.
Successively, during an intermediate stage called "transfer", the wire is transferred from the above mentioned large coils to smaller reels, where it is wound to form coils having size and weight suitable for the wholesale market.
The latter reels are generally made of wood and/or plastic material and are constituted by a substantially cylindrical tubular body provided at its ends with two lateral containment flanges.
The winding operation is performed by winding machines, of which several construction variants are known.
According to one of said variants, the machine comprises a frame resting on the ground, associated with a reel and a motor suited to set the reel rotating around its longitudinal axis.
The machine also comprises a feeding head, slidingly associated with the frame according to a direction that is parallel to the above mentioned longitudinal axis of the reel, which slidingly supports the wire.
The wire is fixed to the reel and, due to the rotation of the latter, is wound around it, guided by the feeding head.
Said feeding head, at the same time, moves with alternate motion and constant speed from one side of the reel to the other, in such a way as to displace the wire winding point and wind, on several overlapping layers, substantially helical turns positioned side by side.
The machine described above poses a limit to the winding thickness that can be obtained, that is, to the number of turns that can be wound around a given reel.
In fact, the feeding head guiding the wire is located at a certain distance from the reel. Therefore, the feeding head cannot assure a precise positioning of the wire on the reel.
As a consequence of the above, variations in the diameter of the wire and/or irregularities of the reel surface, which are rather common in wooden and/or plastic reels and in electric wires, cause the turn to deviate from its ideal path.
For this reason, the further drawback of one turn overlapping the adjacent one may arise, which would further affect the regularity of the winding.
It is easy to understand that said irregularities affect the winding results and limit the number of turns that can be obtained, so that the turns do not fill the reel completely.
Furthermore, the irregularities are transmitted to the successive winding layers, thus producing a cascade effect.
In a known construction variant, the winding machine comprises a sensor suited to determine the position of the turn being wound, according to which the advance of the feeding head is controlled, moment by moment.
This method, though preventing the turns from overlapping, has the limitation that it is suitable only for wires with perfectly circular section and almost constant diameter, like for example in the case of welding wires.
In fact, when the wires have variable diameter, the pitch of the turns varies accordingly, thus generating an irregular winding.
Both the solutions described above pose the further drawback that the turns in each layer cross the turns in the underlying layer and can thus be subjected to deviations due to the effect of the depressions present between the turns of the latter, which further affects the regularity of the winding.
The present invention aims to overcome all the drawbacks described, which are typical of the winding machines of known type.
In particular, it is a first object of the invention to develop a method for winding a filiform element, like for example an electric wire, into a coil on a supporting body, for example a wooden reel, which makes it possible to obtain more regular turns compared to the winding methods of known type, even when the surface of the supporting body and/or the section of the filiform element are irregular.
It is a further object of the invention to obtain a thicker winding than that obtained with the known methods, in such a way as to increase the length of the filiform element wound around a given supporting body. The objects described above are achieved by a winding method in accordance with the main claim, to which the reader should refer for the sake of brevity.
The objects described above are also achieved by a winding machine in accordance with claim 13).
Other details of the method and machine that are the subjects of the invention are described in the corresponding dependent claims.
Advantageously, the increased length of filiform element wound, with the same coil size, makes it possible to reduce the number of coils to be handled in warehouses, thus reducing also the space occupied and the transport costs.
Still advantageously, thanks to the regularity of the turns the coil has a pleasant appearance.
The above-mentioned objects and advantages will be highlighted in greater detail in the following description of a preferred embodiment of the invention, which is provided as an example without limitation, with reference to the attached drawings, wherein:
- Figure 1 shows an axonometric view of the winding machine that is the subject of the invention;
- Figure 2 shows an enlarged detail of Figure 1 ;
- Figures from 3 to 9 show a schematic view of a corresponding number of operating phases of the method of the invention implemented by the machine shown in Figure 1.
As shown in Figure 1 , according to the method of the invention the filiform element W is wound into a coil 2 around a supporting body 3, which defines a longitudinal axis X and is provided with a lateral flange 3a, 3b at each end.
The supporting body 3 is preferably a circular reel, but the method is also suited for use with supporting bodies with non-circular section, for example oval or prismatic section, as in the case of supporting bodies obtained by joining several wooden strips.
The filiform element W is preferably an electric wire, even though it may be any item suited to be wound into coils, like for example a hose, a rope, or the like.
The filiform element W can clearly have any diameter.
According to the method of the invention, one end Wa of the filiform element W is fixed to the surface 4 of the supporting body 3, against a first lateral flange 3a.
Fixing is preferably obtained by means of an adhesive tape, even if it can be obtained using other fixing means, or by inserting the filiform element W into a hole made in the supporting body 3, or with another equivalent procedure.
The supporting body 3 is then set rotating around its longitudinal axis X in the direction R, in order to wind the filiform element W around the surface of the supporting body itself and thus form a first layer of turns S, Sa, as shown in
Figure 3, which shows a front view of the coil 2.
Rotation continues in order to wind up other layers of turns, each one of which overlaps the previous layer, as shown in Figure 9.
Clearly, any number of layers may be wound up and such number will depend, for example, on the diameter d of the filiform element W, as well as on the geometry of the supporting body 3.
According to the invention, as shown in Figure 3, during winding of the first layer and at each 360° rotation corresponding to the winding up of one turn S, the following operations are performed: a) for a predetermined angle of 300°, the tangent point P of the filiform element W on the surface 4 of the supporting body 3 is maintained lying on a reference plane H perpendicular to the longitudinal axis X of the supporting body 3, that is, substantially parallel to the flanges 3a, 3b, to wind a first length S1 of the turn S; b) for the remaining 60°, the tangent point P is displaced towards the second lateral flange 3b of a predefined distance Z and at right angles to said reference plane H, in order to wind a second length S2 of the turn S and position the tangent point P at the beginning of the successive turn.
The operation described under point b) is not performed for the last turn of the first layer, since this is arranged against the second flange 3b, as will be clearer below.
It is evident that the predefined displacement distance Z corresponds to the pitch of the turns Sa, where the first length S1 is substantially parallel to the flanges 3a, 3b while the second length S2 defines a deviation angle Ad with respect to the first length S1.
Consequently, each pair of adjacent turns Sa defines, on the surface of the first layer, a depression suitable for housing a corresponding turn of the successive layer, thus allowing a regular winding result to be achieved, according to the object of the invention.
According to different embodiments of the method of the invention, the above mentioned predetermined angle can clearly assume any value less than 360°. However, it has been found that the value of 300° indicated above ensures the best results in terms of winding regularity, with flexible elements W having various diameters d.
The position of the tangent point P with respect to the reference plane H perpendicular to the longitudinal axis X of the supporting body 3 is established, moment by moment, during winding of the first layer, via guide means 9 arranged in contact with the filiform element W in proximity to the point P of tangency with the supporting body 3, visible in detail in Figure 2. This allows the turns Sa of the first layer to be arranged in precise positions at equidistant intervals, to the benefit of the regularity of the successive layers. According to the method of the invention, a predefined number N of turns Sa is wound in the first layer, based on the formula:
N = INT(U/d), where U is the usable width of the supporting body 3 while d is the diameter of the filiform element W.
In particular, the usable width U is defined as the distance D between the lateral flanges 3a, 3b of the supporting body 3, minus half the diameter d of the filiform element W:
U = D - d/2.
Furthermore, the predefined displacement distance Z between two adjacent turns Sa is established as the ratio between the usable width U and the predefined number of turns N, according to the formula:
Z = U / N.
The above clearly shows that between the last turn of the first layer and the second flange there is a residual space equal to half of the diameter d of the filiform element W.
This makes it possible to wind the second layer staggered with respect to the first layer by half a diameter d, with each of its turns Sa arranged at the level of the depression between two adjacent turns Sa of the first layer. It is evident that the same situation is repeated for the successive layers and that therefore all the layers will comprise the same number of turns N as the first layer.
The above makes it possible to achieve the object of obtaining an orderly winding and thick turns, thicker than those obtainable with the known winding methods, maintaining the same dimensions of the filiform element W and of the supporting body 3.
Furthermore, to advantage, the above mentioned arrangement of the turns Sa allows coils 2 to be obtained that have a more orderly aspect than those obtained with the known methods.
During winding of the coil 2, the filiform element W is kept tensioned for at least one length T adjacent to the coil 2 itself, as shown in Figure 4, which is a top view of the coil 2.
The tensioned length T defines, with respect to the reference plane H corresponding to the last turn S wound, an angle of incidence Ai smaller than 90°, on the side corresponding to the advance direction of the layer being wound.
During winding of the first layer, the above mentioned angle of incidence Ai is maintained preferably greater than or equal to the deviation angle Ad, so that the filiform element W remains constantly in contact with the guide means 9, to the benefit of winding precision.
On the contrary, during winding of the last turn of the first layer, the tensioned length T of the filiform element W is preferably arranged aligned with the reference plane H of the last turn.
This advantageously makes it possible to avoid any friction between the tensioned length T and the second flange 3b of the supporting body 3, since friction could damage the surface of the filiform element W and affect the regularity of the winding.
During winding of the second length S2 of the above mentioned last turn of the first layer, the filiform element W overlaps the second-last turn, thus determining the start of the successive layer, as shown in Figure 6.
It is evident that the same situation will be repeated in an analogous manner for the successive layers.
As shown in Figures 5 and 6, the method requires, at least for the first layer, measurement of the difference in height between the turn S being wound and one or more wound turns Sa, in such a way as to identify the moment at which the above mentioned overlapping takes place.
Advantageously, this makes it possible to establish with precision the start of the winding of the first turn of the second layer, in such a way as to be able to synchronize the movement of the tensioned length T with the rotation of the supporting body 3 and correctly adjust the angle of incidence Ai.
It is obvious that in different variants of the method of the invention the above mentioned measurement can be performed several times during the winding process, thus allowing greater precision to be obtained.
During winding of the turns Sa belonging to the layers after the first one, the tensioned length T is maintained in a slightly forward position with respect to the turn S being wound, thus defining an angle of incidence Ai different from zero, as can be seen in Figure 9.
This advantageously makes it possible to ensure optimal guide of the filiform element W, in particular during winding of the second length S2 of the turns Sa, which defines a deviation angle Ad equal to that of the turns of the first layer.
In other embodiments of the method of the invention during winding of the first length S1 of the turns Sa of the layers after the first one, the tensioned length T can even maintain an angle of incidence Ai equal to zero.
Clearly, variants of the method of the invention may comprise further secondary operations, like for example brushing of the surface of the filiform element W during winding, intended to remove any residues of dirt left from previous processing stages, cutting of the filiform element at the end of winding, continuity test in the case of electric wires, etc.
The above mentioned operations, normally used in winding processes, are well known to sector technicians.
The method described herein is particularly suited to be applied using a winding machine 1 that, as shown in Figure 1 , comprises a frame 1a resting on the ground, with which means 5 for sustaining the supporting body 3 are associated.
The machine also comprises driving means 6, preferably an electric motor, for rotating the supporting body 3 around its longitudinal axis X, associated with the sustaining means 5.
The winding machine 1 further comprises a head 7 that feeds the filiform element W to the coil 2, said head being slidingly associated with the frame 1a via first sliding means 8 that define a first operating direction L parallel to the longitudinal axis X of the supporting body 3.
The first sliding means 8, associated with first actuator means 8a, make it possible to modify the position of the feeding head 7 with respect to the supporting body 3, so that the tensioned length T of the filiform element W remains substantially aligned with the turn S being wound.
According to the invention and as shown in greater detail in Figures 2 and 3, the feeding head 7 comprises guide means 9 arranged in contact with the filiform element W in proximity to its point P of tangency with the surface 4 of the supporting body 3.
The above mentioned guide means 9 allow the tangent point P to be maintained moment by moment in the position required by the method of the invention as described above.
In particular, the guide means 9 comprise a guide plate 10 where it is possible to identify a surface 10a of contact with the filiform element W that is preferably perpendicular to the surface 4 of the supporting body 3.
The guide plate 10 is associated with the feeding head 7 via second sliding means 11 that define a second operating direction L1 perpendicular to the longitudinal axis X of the supporting body 3, in their turn associated with second actuator means not represented herein.
Preferably, the second actuator means 11 allow the guide plate 10 to perform slight movements in the second operating direction L1, so that it can remain in contact with the surface 4 of the supporting body 3 even when this is not cylindrical, following its irregularities.
The measurement of the difference in height required by the method of the invention is preferably performed by means of a measuring head 12.
This is slidingly associated with the feeding head 7 via third sliding means 13 according to a third operating direction L2 perpendicular to the longitudinal axis X and preferably parallel to the second operating direction L1, along which it is set moving via third actuator means not represented herein.
The measuring head 12 comprises at least one first feeler element 14, preferably a disc 14a, positioned in contact with the turn S being wound, and a second feeler element 15, preferably a roller 15a, placed in contact with the previous turns Sa already wound.
The first feeler element 14 is slidingly associated with the measuring head 7 according to a sliding direction parallel to the third operating direction L2, in such a way as to be able to move in relation to the second feeler element 15.
The feeding head 7 comprises also a wire guide unit 16, operatively connected to the feeding head 7 via connection means 17, with which the filiform element W is slidingly associated.
In particular, the filiform element W slides between a pair of circular bodies 20,
21 facing each other and rotatingly associated with the wire guide unit 16.
As regards the connection means 17, they comprise fourth sliding means 18 that slide along a direction parallel to the longitudinal axis X, associated with fourth actuator means not represented herein.
In this way, the wire guide unit 16 can slide rapidly and independently of the position of the feeding head 7 and of the guide means 9 associated with it.
Advantageously, this makes it possible to modify the angle of incidence Ai of the tensioned length T of the filiform element W in relation to the turn S being wound, at the same time maintaining the guide means 9 in the correct position.
The connection means 17 preferably comprise also fifth sliding means 19 that make the wire guide unit 16 slide along a direction perpendicular to the longitudinal axis X, associated with fifth actuator means not represented herein.
Said fifth sliding means 19 allow the tensioned length T to be oriented vertically, as shown in Figures 7 and 8, thus achieving the advantages that are described below.
Preferably, the sliding means 8, 11, 13, 18, 19 mentioned above are linear guides, while the corresponding actuator means can be, for example, gear motors, hydraulic cylinders, worm screws and/or other equivalent means with which sector technicians are well acquainted.
The machine 1 comprises also a control unit, not represented herein, operatively connected to the feeler elements 14, 15, to the driving means 6 and to the actuator means in order to coordinate the movements of the machine 1 during winding.
Preferably, the machine 1 comprises control means, operatively connected to the above mentioned control unit, that allow the operator to set the operating parameters for the winding process, including, for example, the dimensions of the supporting body 3, the diameter of the filiform element W, the number N of turns to be wound, the winding speed, etc.
In practice, and as shown in Figure 3, after fixing one end Wa of the filiform element W to the surface 4 of the supporting body 3, the latter is set rotating around its longitudinal axis X in the direction R, so as to wind up the first layer of turns. At the same time, the feeding head 7 slides in the first operating direction L, driving with itself the guide plate 10.
During rotation, the guide plate 10 remains in contact with the filiform element W so as to define, moment by moment, the point where it is to be laid, that is, the tangent point P.
During winding of each second length S2 of the turns Sa of the first layer, the feeding head 7 is moved and the guide plate 10 is moved with it intermittently along the first operating direction L, with movements corresponding to the above mentioned predefined distance Z.
As shown in Figure 4, the wire guide unit 16 is constantly maintained in a forward position with respect to the turn S being wound, by operating on the fourth actuator means to maintain the angle of incidence Ai of the tensioned length T of the filiform element W greater than the deviation angle Ad of the turns S, Sa.
Furthermore, the tensioned length T is kept horizontal, as shown in Figure 7, to improve the conditions under which the filiform element W is guided.
When the first layer is almost complete, preferably during winding of the last turn, the guide plate 10 is moved away from the supporting body 3 while the measuring head 12 is moved near it, as shown in Figure 5.
At the same time, the tensioned length T of the filiform element W is aligned to the turn S being wound, by moving the wire guide unit 16 parallel to the longitudinal axis X of the supporting body 3.
At the moment when the filiform element W overlaps the first layer, shown in
Figure 6, the disc 14a of the measuring head 12, which is in contact with the turn S being wound, is lifted with respect to the roller 15a, thus signalling to the control unit that creation of the second layer has started.
The control unit of the machine 1 can thus synchronize the movement of the feeding head 7 with the beginning of the individual turns.
At this point, the measuring head 12 is moved away from the supporting body 3 and the feeding head 7 starts moving in the opposite direction, in order to wind up the second layer, as shown in Figure 9.
During winding of the second layer, the movement of the feeding head 7 is constant, with the wire guide unit 16 arranged in a slightly forward position with respect to the turn S being wound.
It is evident, however, that according to other embodiments of the machine 1, during winding of the second layer and of the successive layers the feeding head 7 can move intermittently, analogously to what occurs for the winding of the first layer.
The filiform element W spontaneously fits in the depressions between the turns Sa of the previous layer, with no need to be guided by the guide plate 10.
It is clear that the successive layers will be wound in an analogous manner and the feeding head 7 will be moved alternately in the two opposite directions along the first operating direction L.
Furthermore, during winding of the layers following the first one, the tensioned length T of the filiform element W will be arranged as shown in Figure 8, that is, by reducing curvatures to the minimum, thus allowing the winding speed to be increased.
Practical tests carried out by the inventor showed that, for a given supporting body and a given filiform element, the method of the invention makes it possible to increase the thickness of the winding by up to 20% compared to the known winding methods, increasing by the same percentage also the quantity of filiform element wound.
The above shows that the method and the machine of the invention as described above achieve the set objects.
In fact, the invention achieves the object of carrying out the winding of a filiform element into a coil that is more regular than allowed by the known methods, even if the filiform element and/or the supporting body present irregularities.
The regularity of the turns and the winding precision that follows make it possible to achieve the further object of obtaining windings that are thicker than those obtained with the known methods.
Upon implementation, further changes or construction variants of the method and the machine of the invention - that are not described herein and not represented in the drawings - may be carried out.
Said changes or construction variants must all be considered protected by the present patent, provided that they fall within the scope of the claims expressed below.
Where technical features mentioned in any claim are followed by reference signs, those reference sings have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.

Claims

1) Method for winding a filiform element (W) into a coil (2) on a supporting body (3) defining a longitudinal axis (X) and provided with a lateral flange (3a, 3b) at each end, said method comprising the following operations:
- fixing one end (Wa) of said filiform element (W) to the surface (4) of said supporting body (3), against a first lateral flange (3a);
- setting said supporting body (3) rotating around said longitudinal axis (X) to wind a first layer of turns (S, Sa) of said filiform element (W) around said supporting body (3);
- continuing said rotation to wind other layers of said turns (S, Sa), each one of said layers overlapping the previous one; characterized in that it comprises also the following operations during winding of said first layer: a) maintaining the tangent point (P) between said filiform element (W) and the surface (4) of said supporting body (3) on a reference plane (H) perpendicular to said longitudinal axis (X) of said supporting body (3) during winding of each one of said turns (S, Sa) and for a predefined angle smaller than 360°, to wind a first length (S1) of said turn (S, Sa); b) displacing said tangent point (P) of a predefined distance (Z) at right angles to said reference plane (H) and towards said second lateral flange (3b) during the remaining part of each 360° rotation, except for the last turn of said first layer, to wind a second length (S2) of said turn (S, Sa); c) repeating the operations a) and b) until completing said first layer.
2) Winding method according to claim 1), characterized in that the position of said tangent point (P) with respect to said reference plane (H) is established via guide means (9) arranged in contact with said filiform element (W) in proximity to said tangent point (P).
3) Winding method according to any of the previous claims, characterized in that, at least on said first layer, said second length (S2) of each turn (S, Sa), except for the last one, defines a deviation angle (Ad) with respect to said first length (S1) of said turn (S, Sa).
4) Winding method according to claim 3), characterized in that said first layer comprises a predefined number of turns (N) equal to the whole part of the ratio between a usable width (U) of said supporting body (3) and the diameter (d) of said filiform element (W), said usable width (U) being defined as the distance (D) between said lateral flanges (3a, 3b) minus half the diameter (d) of said filiform element (W).
5) Winding method according to claim 4), characterized in that said predefined displacement distance (Z) is equal to the ratio between said usable width (U) and said predefined number of turns (N).
6) Winding method according to claim 5), characterized in that each one of said layers comprises the same number of turns as said first layer.
7) Winding method according to any of the claims from 3) to 6), characterized in that said filiform element (W) is maintained tensioned for at least one length (T) adjacent to said coil (2) during its winding.
8) Winding method according to claim 7), characterized in that said tensioned length (T) defines an angle of incidence (Ai) smaller than 90° in relation to the reference plane (H) corresponding to the last turn (S) wound, arranged according to the advance direction of the layer to which said wound turn (S) belongs.
9) Winding method according to claim 8), characterized in that said angle of incidence (Ai) is greater than or equal to said deviation angle (Ad) during winding of said first layer.
10) Winding method according to any of the previous claims, characterized in that it includes measurement of the difference in height between the turn (S) being wound and one or more wound turns (Sa) of the same layer to which said turn (S) being wound belongs.
11) Winding method according to any of the previous claims, characterized in that said filiform element (W) is an electric wire.
12) Machine (1) for winding a filiform element (W) into a coil (2) on a supporting body (3) defining a longitudinal axis (X) and provided with a lateral flange (3a, 3b) at each end, comprising:
- a frame (1a) resting on the ground;
- means (5) for sustaining said supporting body (3) associated with said frame (1a);
- driving means (6) for rotating said supporting body (3) around said longitudinal axis (X), associated with said sustaining means (5);
- a head (7) for feeding said filiform element (W) to said coil (2), slidingly associated with said frame (1a);
- first means (8) for sliding said feeding head (7) according to a first operating direction (L) parallel to said longitudinal axis (X) of said supporting body (3);
- first actuator means (8a) associated with said first sliding means (8); characterized in that said feeding head (7) comprises guide means (9) arranged in contact with said filiform element (W) in proximity to the point (T) of tangency of said filiform element (W) with the surface (4) of said supporting body (3).
13) Winding machine (1) according to claim 12), characterized in that said guide means (9) comprise a guide plate (10) that defines a surface (10a) of contact with said filiform element (W) to determine the position of said tangent point (P) along said first operating direction (L).
14) Winding machine according to claim 13), characterized in that it comprises second means (11) for sliding said guide plate (10) on said feeding head (7) associated with second actuator means to define for said guide plate (11) a second operating direction (L1) perpendicular to said longitudinal axis (X).
15) Winding machine (1) according to any of the claims from 12) to 14), characterized in that said feeding head (7) comprises also a measuring head (12), slidingly associated with said feeding head (7) via third sliding means (13) provided with third actuator means to define a third operating direction (L2) at right angles to said longitudinal axis (X).
16) Winding machine (1) according to claim 15), characterized in that said measuring head (12) comprises at least one first feeler element (14) placed in contact at least with the turn (S) of said coil (2) being wound and a second feeler element (15) placed in contact with one or more preceding turns (Sa) of said coil.
17) Winding machine (1) according to claim 16), characterized in that said first feeler element (14) is slidingly associated with said measuring head (12) according to a sliding direction parallel to said third operating direction (L2).
18) Winding machine (1) according to any of the claims 16) or 17), characterized in that said first feeler element (14) is a disc (14a).
19) Winding machine (1) according to any of the claims from 16) to 18), characterized in that said second feeler element (15) is a roller (15a).
20) Winding machine (1) according to any of the claims from 12) to 19), characterized in that said feeding head (7) also comprises at least one wire guide unit (16), operatively connected to said feeding head (7) via connection means (17), with which said filiform element (W) is slidingly associated.
21) Winding machine (1) according to claim 20), characterized in that said connection means (17) comprise fourth sliding means (18) that define a direction parallel to said longitudinal axis (X), associated with fourth actuator means.
22) Winding machine (1) according to claim 21), characterized in that said connection means (17) also comprise fifth sliding means (19) that slide according to a direction perpendicular to said longitudinal axis (X), associated with fifth actuator means.
23) Winding machine (1) according to any of the claims from 20) to 22), characterized in that said wire guide unit (16) comprises at least one pair of circular bodies (20, 21) facing each other and rotatingly associated with said wire guide unit (16).
24) Winding machine (1) according to any of the claims from 12) to 23), characterized in that it comprises a control unit operatively connected to said feeler elements (14, 15), to said driving means (6) and to said actuator means.
PCT/IB2008/000913 2007-04-17 2008-04-15 Method for winding a filiform element into a coil and winding machine implementing said method. WO2008125965A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITVI20070112 ITVI20070112A1 (en) 2007-04-17 2007-04-17 METHOD OF WRAPPING OF A FILIFORM ELEMENT IN COIL AND WRAPPING MACHINE REALIZING THIS METHOD
ITVI2007A000112 2007-04-17

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ITVI20090151A1 (en) * 2009-06-23 2010-12-24 C Z Elettronica S R L METHOD OF WRAPPING OF A FILIFORM ELEMENT IN A REFINED COIL
ITUA20162901A1 (en) * 2016-04-26 2017-10-26 Cz Tech S R L WINDMILL MACHINE AND METHOD OF WINDING A ROLLED COIL
CN110540103A (en) * 2019-10-16 2019-12-06 东莞市蓝姆材料科技有限公司 Edge-camber material roll and winding method thereof
US20240092608A1 (en) * 2019-10-29 2024-03-21 Ube Exsymo Co., Ltd. Wound yarn package and manufacturing method thereof

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ITUA20162901A1 (en) * 2016-04-26 2017-10-26 Cz Tech S R L WINDMILL MACHINE AND METHOD OF WINDING A ROLLED COIL
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US20240092608A1 (en) * 2019-10-29 2024-03-21 Ube Exsymo Co., Ltd. Wound yarn package and manufacturing method thereof

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