WO2015191932A1

WO2015191932A1 - System and method for securing free end of wound cable

Info

Publication number: WO2015191932A1
Application number: PCT/US2015/035439
Authority: WO
Inventors: Daniel L. Shelander
Original assignee: Windak Inc.
Priority date: 2014-06-11
Filing date: 2015-06-11
Publication date: 2015-12-17
Also published as: US20150360800A1

Abstract

A system for securing a free end (22) of a cable (24) wound on a spool (26) includes a spooling machine (10) having at least one spooling head (20) for winding a length of the cable (24) onto the spool (26) and a stretch wrap applicator (30) for securing the free end (22) of the cable (24) on the spool (26) with stretch wrap (40) that is pinched between the free end (22) of the cable (24) and the outermost windings of the cable (24) wound on the spool (26). A stretch wrap applicator (30) for a spooling machine (10) having at least one spooling head (20) includes a housing (34), a roll of stretch wrap (40) disposed within the housing (34) and a pulling clamp (32) for gripping and pulling a starting end (42) of the stretch wrap (40) so as to position the stretch wrap (40) between a spool (26) of wound cable (24) having outermost windings and a free end (22) of the cable (24) wound on the spool (26). A method for securing the free end (22) of a cable (24) wound on a spool (26) includes providing the spooling machine (10) and the stretch wrap applicator (30), moving the pulling clamp (32) from an initial position around a free end (22) of the cable (24), gripping a starting end (42) of the stretch wrap (40), moving the pulling clamp (32) and the stretch wrap (40) back to the initial position with the stretch wrap (40) disposed between the free end (22) and the outermost windings of the cable (24) and moving the pulling clamp (32) in a downward direction so as to pinch the stretch wrap (40) within a nip defined between the outermost windings and the free end (22) of the cable (24).

Description

SYSTEM AND METHOD FOR SECURING

FREE END OF WOUND CABLE

CROSS-REFERENCE TO RELATED APPLICATION

[0001 ] This International (PCT) application claims the benefit of priority to United States Provisional Patent Application No. 62/01 1,013 filed on June 1 1, 2014, the entire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to systems, apparatus and methods for securing the free end of wound cable. More particularly, the invention is a system and method for securing the free end of a length of an elongate, flexible cable that is wound onto a spool by a spooling machine. The free end of the cable is secured using stretch wrap that is automatically applied to a spool of wound cable as the cable is being cut so that the leading end of the stretch wrap is nipped between the spool of wound cable and the free end of the cable. In an exemplary embodiment, the stretch wrap system is mounted horizontally and movable in a transverse direction to service at least two cable spooling stations on a spooling machine.

BACKGROUND OF THE INVENTION

[0003] It is common practice for lengths of elongate, flexible components, such as strands of wire, tubing or cable to be wound onto a spool. Oftentimes, the free end of the wound cable is retained on the spool by a relatively thin layer of stretch wrap that is wrapped around the spool after the desired length of cable has been wound onto the spool. Typically, the free end of the cable is temporarily held in place and a rotary arm is moved around a stationary spooling head to wrap the stretch wrap onto the spool of wound cable. The stretch-wrapped spool of wound cable is then removed from the spooling head of the spooling machine and transferred into a container or onto a pallet for transporting a plurality of the cable spools to an end user. [0004] Spooling machines are known for automatically winding a length of elongate, flexible cable, for example coaxial cable or fiber optic cable, onto a spool and for automatically applying stretch wrap to the spool of wound cable. A spooling machine including fully automatic dual take-ups for on-line or off-line packaging of cable products is available from the Hall Industries division of the MGS Group having its corporate offices located in Rome, New York, USA. The MGS/Hall spooling machine includes two winding stations for winding a length of cable onto a spool and for applying a relatively thin layer of stretch wrap to the spool of wound cable to secure the free end of the cable onto the spool. Each winding station has a spooling head that is provided with a positive automatic stretch wrap applicator. The stretch wrap applicator operates to apply the stretch wrap to the spool of wound cable so that the starting end of the stretch wrap is positively pinched under the free end of the cable just prior to the conclusion of the winding cycle.

[0005] The automatic stretch wrap applicator provided at each winding station of the MGS/Hall spooling machine includes two clamps and a push-down roller. The first stretch wrap clamp operates to pull the starting end of the stretch wrap from a stretch wrap roll to a position that is relatively close to the spool of wound cable. The push-down roller next operates to move the stretch wrap to the opposite side of the wound cable. The second stretch wrap clamp then operates to grab the stretch wrap from the opposite side and to pull the stretch wrap back across the spool of wound cable. However, a number of disadvantages, deficiencies and problems are associated with the automatic stretch wrap applicator of the MGS/Hall spooling machine. The MGS/Hall stretch wrap applicator requires an excessive number of separate components, which results in high cost and reduced reliability of the applicator. In addition, the MGS/Hall stretch wrap applicator does not pull the stretch wrap between layers of the wound cable. Therefore, the relatively thin layer of stretch wrap can slip on a wound cable having an excessively smooth or slick jacket, and as a result, not be pulled around the spool of wound cable. As previously mentioned, the MGS/Hall spooling machine utilizes two vertically oriented spooling heads and requires a separate stretch wrap applicator for each spooling head. Since the spooling heads are oriented vertically, the free end of the cable can bend downwardly under the influence of gravity relative to the feed direction of the stretch wrap. Thus, the free end of the cable can extend outwardly from beneath the stretch wrap and potentially snag causing premature removal of the stretch wrap. Furthermore, the use of a separate stretch wrap applicator for each of the two spooling heads unnecessarily duplicates components of the spooling machine and increases acquisition, maintenance and operating costs.

SUMMARY OF THE INVENTION

[0006] The present invention is a system and method for winding a length of cable onto a spool and automatically applying stretch wrap onto the spool of wound cable to secure the free end of the cable on the spool. More particularly, the invention is a stretch wrap applicator for a spooling machine having two spooling heads and a method for applying stretch wrap onto a spool of wound cable at each spooling head to secure the free end of the cable on the spool.

[0007] In one aspect, the invention is embodied by a system including a spooling machine having at least one spooling head for winding a length of an elongate, flexible component onto a spool and a stretch wrap applicator configured for and operable for securing a free end of the elongate, flexible component on the spool with stretch wrap. The stretch wrap applicator pinches the stretch wrap between the free end and outermost windings of the elongate flexible component wound on the spool. In one embodiment, the spooling machine has two spooling heads and the stretch wrap applicator is mounted on the spooling machine for transverse movement relative to the spooling heads. The spooling machine may have a rail and a drive mechanism and the stretch wrap applicator may be operably coupled with the drive mechanism for transverse movement along the rail relative to the two spooling heads. The two spooling heads of the spooling machine may be positioned at transversely spaced-apart locations along the rail and the stretch wrap applicator may be operable for transverse movement between the spooling heads. In another embodiment, the stretch wrap applicator includes a pulling clamp configured for and operable for being moved from an initial position around the free end of the elongate, flexible component wound on the spool and into engagement with a starting end of the stretch wrap. The pulling clamp is further configured for and operable for moving back to the initial position while gripping the starting end of the stretch wrap such that the stretch wrap is disposed between the free end and the outermost windings of the elongate, flexible component wound on the spool. The pulling clamp is further configured for and operable for moving downwardly relative to the elongate, flexible component wound on the spool so that the stretch wrap is pinched within a nip defined between the outermost windings of the elongate, flexible component and the free end of the elongate, flexible component.

[0008] In another aspect, the invention is embodied by a stretch wrap applicator for a spooling machine having at least one spooling head. The stretch wrap applicator includes a housing, a roll of stretch wrap disposed within the housing and a pulling clamp configured for and operable for gripping and pulling a starting end of the roll of stretch wrap so as to position the stretch wrap between a spool of wound cable having outermost windings and a free end of the cable wound on the spool. The stretch wrap is pinched within a nip defined by the outermost windings of the cable wound on the spool and the free end of the cable. The pulling clamp is further configured for and operable for moving downwardly relative to the spool of wound cable so as to dispose the stretch wrap between the outermost windings of the cable wound on the spool and the free end of the cable. In one embodiment, the pulling clamp is mounted on an angled rail that is movably attached to the housing with a predetermined angle such that the pulling clamp and a starting end of the stretch wrap are moved in a generally tangential direction relative to an outer periphery of the cable wound on the spool. The pulling clamp is further configured for and operable for releasing the starting end of the stretch wrap in contact with at least a portion of the outermost windings of the cable wound on the spool so that the stretch wrap disposed between the outermost windings of the cable and the free end of the cable is wrapped around the spool as the remaining length of the cable is wound onto the spool.

[0009] In yet another aspect, the invention is embodied by a method for securing the free end of an elongate, flexible component wound onto a spool. The method includes providing a spooling machine having at least one spooling head for winding a length of the elongate, flexible component onto the spool and providing a stretch wrap applicator operably coupled with the at least one spooling head for applying stretch wrap to the elongate, flexible component wound on the spool. The stretch wrap applicator includes a pulling clamp and a length of the stretch wrap. The method further includes moving the pulling clamp from an initial position around a free end of the elongate, flexible component wound on the spool. The method further includes gripping a starting end of the stretch wrap with the pulling clamp. The method further includes moving the pulling clamp and the starting end of the stretch wrap back to the initial position with the stretch wrap disposed between the free end of the elongate, flexible component and outermost windings of the elongate, flexible component. The method further includes moving the pulling clamp in a downward direction so as to pinch the stretch wrap within a nip defined between the outermost windings of the elongate, flexible component and the free end of the elongate, flexible component. The method further includes cutting the free end of the elongate, flexible component and wrapping the stretch wrap around the outermost windings of the elongate, flexible component until the free end of the elongate, flexible component is secured by the stretch wrap. In one embodiment, the spooling machine includes two spooling head and a transverse rail and the stretch wrap applicator is configured for and operable for moving in a transverse direction along the rail relative to the spooling heads. The stretch wrap applicator moves between a first spooling head of the spooling machine and a second spooling head of the spooling machine subsequent to securing the free end of the elongate, flexible component wound on a spool of the first spooling head. In another embodiment, the pulling clamp is mounted on an angled rail that is movably attached to the housing with a predetermined angle such that the pulling clamp and a starting end of the stretch wrap are moved in a generally tangential direction relative to an outer periphery of the cable wound on the spool.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a front perspective view of a stretch wrap applicator for a spooling machine having two spooling heads that is operable for automatically applying stretch wrap to a spool of wound cable according to an exemplary embodiment of the invention.

[001 1 ] FIG. 2 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving transversely relative to the spooling heads to locate the stretch wrap applicator adjacent to one of the spooling heads having a length of cable wound on a spool.

[0012] FIG. 3 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving transversely relative to the one of the spooling heads to locate the stretch wrap applicator in line with the free end of the wound cable.

[0013] FIG. 4 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving the pulling clamp from an initial position around the free end of the wound cable and into engagement with the starting end of the stretch wrap.

[0014] FIG. 5 is a detailed rear perspective view showing the pulling clamp of the stretch wrap applicator of FIG. 1 in gripping engagement with the starting end of the stretch wrap.

[0015] FIG. 6 is a rear perspective view illustrating the pulling clamp of the stretch wrap applicator of FIG. 1 being moved back to the initial position such that the stretch wrap is disposed between the spool and the free end of the wound cable.

[0016] FIG. 7 A is a front perspective view illustrating the pulling clamp of the stretch wrap applicator of FIG. 1 being moved downwardly relative to the spool of wound cable such that the stretch wrap is pinched within a nip defined by the outermost windings of the cable and the free end of the wound cable.

[0017] FIG. 7B is a rear perspective view corresponding to the front perspective view of FIG. 7A.

[0018] FIG. 8 is a front perspective view illustrating the puling clamp of the stretch wrap applicator of FIG. 1 releasing the starting end of the stretch wrap such that the stretch wrap will be wrapped around the spool of wound cable by the free end of the cable being wound onto the spool.

[0019] FIG. 9 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 cutting the free end of the cable and then subsequently winding the free end of the cable onto the spool beneath the stretch wrap as the stretch wrap is wrapped around the spool of wound cable.

[0020] FIG. 10 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving transversely relative to the spooling head of the spooling machine to thereby wrap the spool of wound cable with the stretch wrap entirely from one outer flange to the other outer flange.

[0021 ] FIG. 11 is a rear perspective view illustrating the spool of wound cable wrapped with the stretch wrap transversely between one outer flange and the other outer flange.

[0022] FIG. 12 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving the stretch wrap cutter into a cutting position relative to the finishing end of the stretch wrap. [0023] FIG. 13 is a rear perspective view showing the finishing end of the stretch wrap being cut by the stretch wrap cutter of the stretch wrap applicator of FIG. 1 and subsequently being wrapped around the spool of wound cable to thereby secure the free end of the wound cable so that the finished spool may be removed from the spooling machine.

[0024] FIG. 14 is a rear perspective view illustrating the stretch wrap applicator of FIG. 1 moving transversely relative to the two spooling heads of the spooling machine to locate the stretch wrap applicator adjacent to the other one of the spooling heads having a length of cable wound on a spool.

[0025] FIG. 15 is a perspective view of a stretch wrap applicator for applying stretch wrap to a coil of a desired length of cable wound onto a spool according to another exemplary embodiment of the present invention.

[0026] FIG. 16 is a perspective view showing the coil engaged by a pair of side grippers of the stretch wrap applicator of FIG. 15.

[0027] FIG. 17 is a perspective view showing the free end of the cable engaged by a cable end holder of the stretch wrap applicator of FIG. 15.

[0028] FIGS. 18-23 are perspective views illustrating the stretch wrap sequence for applying stretch wrap to the coil of wound cable using the stretch wrap applicator of FIG. 15.

[0029] FIGS. 24-26 are perspective views illustrating the coil of wound cable wrapped with stretch wrap moving from the stretch wrap applicator of FIG. 15 to a driven conveyor system for delivering the stretch wrapped coil to a container or a pallet for storage and transport.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

[0030] Referring now to the accompanying drawings, in which like reference characters in the drawing figures refer to the same or similar parts, a spooling machine, indicated generally at 10, having two spooling heads, each indicated generally at 20 with the corresponding winder not depicted for purposes of clarity, and a stretch wrap applicator, indicated generally at 30, is shown in FIGS. 1-14. The single stretch wrap applicator 30 is configured for and operable to secure a free end 22 of a length of cable 24 wound onto a spool 26 by wrapping the spool of wound cable with stretch wrap 40 (see e.g., FIGS. 8-13). In the exemplary embodiments shown and described herein, the stretch wrap applicator 30 is movable transversely relative to the two spooling heads 20 of the spooling machine 10 so that the single stretch wrap applicator is configured for and operable to service both spooling heads. However, as will be readily appreciated by those skilled in the art, if desired each spooling head 20 of the spooling machine 10 may be provided with a separate stretch wrap applicator 30 configured for and operative to secure the free end 22 of a length of cable 24 wound onto a spool 26 at each spooling head. Furthermore, the spooling machine 10, including the stretch wrap applicator 30 may be configured for use with any elongate, flexible component, including without limitation wire, tubing or cable, to form a spool of the wound component, and to thereafter, wrap stretch wrap around the spool of the wound component to secure the free end of the elongate, flexible component on the spool. In preferred embodiments, the elongate, flexible component is a cable, such as coaxial cable or fiber optic cable. Those of ordinary skill will readily understand and appreciate that the spooling machine 10 and the stretch wrap applicator 30 may be used alone or in combination with one another in various other applications without departing from the scope of the invention, as broadly interpreted in light of this written description. For purposes of illustration only, the spooling machine 10 including the spooling heads 20 and the stretch wrap applicator 30 are shown and described herein for use with reference to coaxial or fiber optic cable 24 of the type commonly utilized by an end user in communications applications.

[0031 ] FIG. 1 shows a spooling machine 10 including two spooling heads 20 and a stretch wrap applicator 30 mounted for transverse movement on the spooling machine relative to the spooling heads. As shown, the spooling machine 10 comprises a transversely (i.e., generally horizontal) extending rail 12 and a drive mechanism 14, such as a belt or chain driven by one or more rotating gears, pulleys or the like, configured for and operable for moving the stretch wrap applicator 30 along the rail transversely in a generally horizontal direction relative to the spools 26 of the spooling heads 20.

[0032] FIG. 2 illustrates the stretch wrap applicator 30 being moved transversely relative to the spooling heads 20 of the spooling machine 10 to locate the stretch wrap applicator adjacent to one of the spooling heads on which a length of the cable 24 is being wound onto a spool 26 between a pair of outer flanges 28. The opposing arrows depicted in certain of the drawing figures indicate the generally horizontal direction of movement of the stretch wrap applicator 30 relative to the spooling heads 20 of the spooling machine 10.

[0033] FIG. 3 illustrates the stretch wrap applicator 30 moved transversely relative to the spooling heads 20 of the spooling machine 10 so as to position the stretch wrap applicator in line with the free end 22 of the cable 24 being wound onto the spool 26 between the outer flanges 28.

[0034] FIG. 4 illustrates a pulling clamp 32 of the stretch wrap applicator 30 moved from an initial position shown in FIG. 3 around the free end 22 of the cable 24 being wound onto the spool 26. The pulling clamp 32 is moved from the initial position into engagement with the starting end 42 of a roll of the stretch wrap 40 housed within an interior of a housing 34 of the stretch wrap applicator 30. The pulling clamp 32 may be affixed to the starting end 42 of the stretch wrap 40 in any manner suitable for gripping the starting end sufficiently to unwrap the stretch wrap off the roll of stretch wrap, as will be described in greater detail hereinafter.

[0035] FIG. 5 is a detailed view showing the pulling clamp 32 disposed around the free end 22 of the cable 24 and in gripping engagement with the starting end 42 of the stretch wrap 40.

[0036] FIG. 6 illustrates the pulling clamp 32 of the stretch wrap applicator 30 moved back to the initial position, while gripping the starting end 42 of the stretch wrap 40, such that the stretch wrap is pulled behind the free end 22 of the cable 24. As used herein, the term "behind" is intended to mean that the stretch wrap 40 is disposed between the fee end 22 of the cable 24 and the remaining length of the cable wound on the spool 26. More particularly, the stretch wrap 40 is disposed between the free end 22 of the cable 24 and the outermost windings of the cable already wound onto the spool 26 between the outer flanges 28.

[0037] FIG. 7 A is a front perspective view of the spooling machine 10 illustrating that the pulling clamp 32 of the stretch wrap applicator 30 is next moved downwardly relative to the spool 26 of wound cable 24. The pulling clamp 32 may be moved downwardly in any suitable manner, such as mechanically, electrically or pneumatically. As shown herein, the pulling clamp 32 is mounted on an angled rail 36 that is movably attached to the housing 34 of the stretch wrap applicator 30 with a predetermined angle such that the pulling clamp 32 and the starting end 42 of the stretch wrap 40 are moved in a generally tangential direction relative to the periphery of the cable 24 wound on the spool 26. In this manner, the stretch wrap 40 is pulled downwardly relative to the spool 26 so as to be pinched within a nip defined between the outermost windings of the cable 24 already wound on the spool and the free end 22 of the cable.

[0038] FIG. 7B is a rear perspective view of the spooling machine 10 illustrating the stretch wrap 40 disposed between the outermost windings of the cable 24 and the free end 22 of the cable.

[0039] FIG. 8 is a front perspective view of the spooling machine 10 illustrating the stretch wrap 40 released by the pulling clamp 32 of the stretch wrap applicator 30 with the stretch wrap in contact with at least a portion of the outermost windings of the cable 24 wound on the spool 26. In this manner, the stretch wrap 40 disposed between the outermost windings of the cable 24 and the free end 22 of the cable is next wrapped around the spool 26 of wound cable as the remaining length of the free end of the cable is being wound onto the spool.

[0040] FIG. 9 shows the free end 22 of the cable 24 is cut so that the free end of the cable will be disposed beneath the stretch wrap 40 as the stretch wrap continues to be wrapped around the spool 26 of wound cable.

[0041 ] If desired, the stretch wrap 40 may be moved across the spool 26 of wound cable 24 between the outer flanges 28 of the spool so that the entire width of cable on the spool is covered by the stretch wrap as the stretch wrap is wrapped around the spool. FIG. 10 shows the stretch wrap 40 optionally being moved across the width of the spool 26 to traverse the cable 24 wound on the spool and thereby wrap the entire spool of wound cable with the stretch wrap. FIG. 11 is a rear perspective view showing the entire width of the cable 24 wound onto the spool 26 and optionally wrapped with the stretch wrap 40.

[0042] FIG. 12 is a rear perspective view showing a stretch wrap cutter 38 of the stretch wrap applicator 30 located in a position to cut a finishing end 44 of the stretch wrap 40. The stretch wrap cutter 38 may be any suitable means for cutting stretch wrap 40, such as a blade, hot knife or the like. As shown herein, stretch wrap cutter 38 is a heated cutter configured for and operative to cut the finishing end 44 of the stretch wrap 40 at a desired position so that the pulling clamp 32 of the stretch wrap applicator 30 can subsequently grip another starting end 42 of the stretch wrap 40 for wrapping a length of cable 24 wound onto a subsequent spool 26.

[0043] FIG. 13 is a rear perspective view showing the finishing end 44 of the stretch wrap 40 cut and wrapped around the cable 24 wound onto the spool 26. As a result, the finished cable spool (i.e. a desired length of the cable 24 wound onto spool 26 and wrapped with stretch wrap 40) is available to be removed from the spooling machine 10 and transferred to a shipping container, such as a corrugated box, or to a pallet for being transported with other finished cable spools to an end user, such as an installer of communications cable. Once the finished cable spool is removed from the spooling machine 10, a subsequent spool 26 may be positioned on the spooling head 20 so as to receive the free end 22 of the cable 24 to be wrapped onto the spool and wrapped with the stretch wrap 40, as previously described herein, and form another finished cable spool.

[0044] FIG. 14 is a rear perspective view illustrating the stretch wrap applicator 30 being moved transversely, in the manner previously described, to a location adjacent the other of the two spooling heads 20 of the spooling machine 10. As such, the same stretch wrap applicator 30 is utilized to apply a relatively thin layer of the stretch wrap 40 onto a length of cable 24 wound onto a spool 26 at the other spooling head 20 of the spooling machine 10. In this manner, there is no unnecessary duplication of components of the stretch wrap applicator 30, thereby reducing the overall cost, complexity and maintenance of the stretch wrap applicator and the spooling machine 10. Furthermore, the other spooling head 20 may be utilized to form the subsequent spool 26 of wound cable 24 while the stretch wrap applicator 30 is being utilized to apply (i.e., wrap) the first spool of wound cable with stretch wrap 40.

[0045] A stretch wrap applicator 60 according to another exemplary embodiment of the present invention is shown in FIGS. 15-26. The stretch wrap applicator 60 comprises a pair of servo-driven coil movers 62 operable for moving a length of cable 24 wound onto a spool 26 at a spooling head 20 of the spooling machine 10. Hereinafter, the cable 24 wound onto the spool 26 is also referred to as coil 24, 26.

[0046] FIG. 15 shows the coil 24, 26 gripped between the pair of coil movers 62 just before the length of cable 24 is cut. The coil movers 62 are positioned so as to grip the coil 24, 26 as the cable 24 is cut to create a free end of the cable. If necessary, the coil 24, 26 is rotated up to about one-quarter turn to locate the free end of the cable in an optimum position. When the coil 24, 26 is properly positioned, the coil movers 62 move the coil downwards with the coil supported by a pair of side guides 64.

[0047] As shown in FIG. 16, when the coil 24, 26 is low enough for a pair of side grippers 66 to clear the side guides 64, the side grippers are engaged with the coil in a suitable manner, such as by a pneumatic cylinder. A position sensor, for example a Hall Effect sensor, may be utilized to identify that the side grippers 66 are in the correct position as they move upwards to engage the coil 24, 26. Ideally, the movement of the side grippers 66 into engagement with the coil 24, 26 should be accomplished while the coil is being moved downwards without an additional interruption (stoppage) of the movement of the coil.

[0048] As shown in FIG. 17, when the center 25 of the coil 24, 26 clears the side guides 64, a cable end holder 70 is engaged to hold the free end of the cable 24. A position sensor, for example a Hall Effect sensor, may be utilized to indicate when the cable end holder 70 is in the proper position to engage the free end of the cable 24. Ideally, the movement of the cable end holder 70 into engagement with the free end of the cable 24 should be accomplished while the coil 24, 26 is being moved downwards without an additional interruption (stoppage) of the movement of the coil.

[0049] FIG. 18 shows the coil 24, 26 in the stretch wrap position to begin the stretch wrap process. The starting end of the stretch wrap 40 is held by a gripper 72. The stretch wrap 40 mounted on an orbiter 80 (e.g. rotary arm) is rotated around the coil 24, 26, for example in a counter-clockwise direction. The orbiter 80 may comprise a belt drive 82, a suitable motor, for example a 3 KW AC motor, and a pulse encoder in a known manner. The tension on the stretch wrap 40 may be controlled by a manually adjusted mechanical brake roller 88. In addition, a guide 68 (see e.g., FIG. 19) may be provided for guiding the stretch wrap 40 between the orbiter 80 and the gripper 72. For purposes of convenience, the guide 68 may be disposed, for example, on the orbiter 80.

[0050] As shown in FIG. 19, just before the first revolution of the stretch wrap 40 on the orbiter 80 is completed, the gripper 72 tilts downward. As a result, the starting end of the stretch wrap 40 is secured by the next layer of the stretch wrap. As shown in FIG. 20, when the starting end of the stretch wrap 40 is secured under the next layer of the stretch wrap, the gripper 72 releases the plastic stretch wrap and an air blower is used to force the free end of the cable 24 under the next layer of the stretch wrap.

[0051 ] As shown in FIG. 21, when the stretch wrap 40 is on its final revolution, the open gripper 72 moves back upwards and the roll of stretch wrap 40 is stopped in its home position. As shown in FIG. 22, the finishing end of the stretch wrap 40 is secured by the gripper 72 and the stretch wrap is cut in a suitable manner, for example by a blade, a hot knife or a hot wire driven in a suitable manner, for example by a pneumatic cylinder. The loose finishing end of the stretch wrap 40 is forced against the coil 24, 26 by an air blower.

[0052] FIG. 23 shows that the cable end holder 70 can then release the free end of the cable 24. An upper coil mover spade 74 is moved into position by a pneumatic cylinder to ensure that it is clear for the coil movers 62 to move upwards relative to the coil 24, 26. At this point in time, the coil 24, 26 wrapped in stretch wrap 40 is held in place by the side grippers 66 alone, which are not visible in FIG. 23.

[0053] FIG. 24 illustrates that when a side gripper valve is operated to release the pressure of the side grippers 66 on the stretch wrapped coil 24, 26, the side grippers are not yet opened. The coil 24, 26 is then pushed out from between the side grippers 66 by suitable means, for example a pusher operated by a pneumatic cylinder. As a result, the stretch wrapped coil 24, 26 slides down a guide 89 onto a driven conveyor system 90, as shown in FIG. 25 and FIG. 26. The pusher then moves back inwards and the side grippers 66 are opened so that the lower coil mover 62 can be moved upwards to repeat the cycle. FIG. 25 and FIG. 26 illustrate how the stretch wrapped coil 24, 26 is moved along the driven conveyor system 90 and dropped into a container, such as a corrugated box (not shown) or onto a pallet for storage and transport, in a manner similar to that previously described with respect to stretch wrap applicator 30.

[0054] The foregoing has described exemplary embodiments of a stretch wrap applicator for a spooling machine having one or more spooling heads for winding a desired length of cable onto a spool and wrapping the finished cable spool with stretch wrap to secure the free end of the cable on the spool. The exemplary embodiments of the present invention described herein are shown and/or illustrated in the accompanying drawing figures. In an exemplary embodiment, a single stretch wrap applicator is transversely moveable on the spooling machine relative to two spooling heads so that the stretch wrap applicator is usable with both of the spooling heads. The stretch wrap applicator includes a pulling clamp for gripping and pulling a starting end of the stretch wrap into a nip between the outermost windings of the cable already wound onto the spool and the free end of the cable. The stretch wrap is then wrapped around the spool of wound cable and the free end of the cable is cut and secured beneath the stretch wrap. In another exemplary embodiment, a stretch wrap applicator includes a pair of coil movers that position a coil of cable wound on a spool relative to the starting end of stretch wrap. The free end of the cable is secured while the stretch wrap mounted on a rotary arm is wrapped around the coil with the free end of the cable secured beneath the stretch wrap. The coil is then released and pushed onto a driven conveyor system to be delivered to a container or a pallet for storage and transport.

Claims

That which is claimed is:

1. A system, comprising: a spooling machine (10) having at least one spooling head (20) for winding a length of an elongate, flexible component (24) onto a spool (26); and a stretch wrap applicator (30) configured for and operable for securing a free end (22) of the elongate, flexible component (24) on the spool (26) with stretch wrap (40); wherein the stretch wrap (40) is pinched between the free end (22) and outermost windings of the elongate flexible component (24) wound on the spool (26).

2. The system of claim 1, wherein the spooling machine (10) comprises two spooling heads (20) and wherein the stretch wrap applicator (30) is mounted on the spooling machine (10) for transverse movement relative to the spooling heads (20).

3. The system of claim 2, wherein the spooling machine (10) further comprises a rail (12) and a drive mechanism (14) and wherein the stretch wrap applicator (30) is operably coupled with the drive mechanism (14) for transverse movement along the rail (12) relative to the two spooling heads (20).

4. The system of claim 2, wherein the two spooling heads (20) of the spooling machine (10) are positioned at transversely spaced-apart locations along the rail (12) and wherein the stretch wrap applicator (30) is operable for transverse movement between the spooling heads (20).

5. The system of claim 1, wherein the stretch wrap applicator (30) comprises a pulling clamp (32) configured for and operable for being moved from an initial position around the free end (22) of the elongate, flexible component (24) wound on the spool (26) and into engagement with a starting end (42) of the stretch wrap (40).

6. The system of claim 5, wherein the pulling clamp (32) is affixed to the starting end (42) of the stretch wrap (40) sufficiently to unwrap the stretch wrap (40) off a roll of the stretch wrap.

7. The system of claim 5, wherein the pulling clamp (32) is further configured for and operable for moving back to the initial position while gripping the starting end (42) of the stretch wrap (40) such that the stretch wrap (40) is disposed between the free end (22) of the elongate, flexible component (24) and the remaining length of the elongate, flexible component (24) wound on the spool (26).

8. The system of claim 7, wherein the stretch wrap (40) is disposed between the free end (22) of the elongate, flexible component (24) and outermost windings of the elongate, flexible component (24) wound on the spool (26).

9. The system of claim 7, wherein the pulling clamp (32) is further configured for and operable for moving downwardly relative to the elongate, flexible component (24) wound on the spool (26) so that the stretch wrap (40) is pinched within a nip defined between the outermost windings of the elongate, flexible component (24) and the free end (22) of the elongate, flexible component (24).

10. The system of claim 9, wherein the pulling clamp (32) is mounted on an angled rail (36) and is moved downwardly along the angled rail (36) such that the pulling clamp (32) and the starting end (42) of the stretch wrap (40) are moved in a generally tangential direction relative to a periphery of the elongate, flexible component (24) wound on the spool (26).

11. A stretch wrap applicator (30) for a spooling machine (10) having at least one spooling head (20, the stretch wrap applicator (30) comprising: a housing (34); a roll of stretch wrap (40) disposed within the housing (34); and a pulling clamp (32) configured for and operable for gripping and pulling a starting end (42) of the roll of stretch wrap (40) so as to position the stretch wrap (40) between a spool (26) of wound cable (24) having outermost windings and a free end (22) of the cable (24) wound on the spool (26).

12. The stretch wrap applicator (30) of claim 11, wherein the stretch wrap (40) is pinched within a nip defined by the outermost windings of the cable (24) wound on the spool (26) and the free end (22) of the cable (24).

13. The stretch wrap applicator (30) of claim 1 1, wherein the pulling clamp (32) is further configured for and operable for moving downwardly relative to the spool (26) of wound cable (24) so as to dispose the stretch wrap (40) between the outermost windings of the cable (24) wound on the spool (26) and the free end (22) of the cable (24).

14. The stretch wrap applicator (30) of claim 13, wherein the pulling clamp (32) is mounted on an angled rail (36) that is movably attached to the housing (34) with a predetermined angle such that the pulling clamp (32) and a starting end (42) of the stretch wrap (40) are moved in a generally tangential direction relative to an outer periphery of the cable (24) wound on the spool (26).

15. The stretch wrap applicator (30) of claim 14, wherein the pulling clamp (32) is further configured for and operable for releasing the starting end (42) of the stretch wrap (40) in contact with at least a portion of the outermost windings of the cable (24) wound on the spool (26) so that the stretch wrap (40) disposed between the outermost windings of the cable (24) and the free end (22) of the cable (24) is wrapped around the spool (26) as the remaining length of the cable (24) is wound onto the spool (26).

16. A method for securing the free end (22) of an elongate, flexible component (24) wound onto a spool (26), the method comprising: providing a spooling machine (10) having at least one spooling head (20) for winding a length of the elongate, flexible component (24) onto the spool (26); providing a stretch wrap applicator (30) operably coupled with the at least one spooling head (20) for applying stretch wrap (40) to the elongate, flexible component (24) wound on the spool (26), the stretch wrap applicator (30) comprising a pulling clamp (32) and a length of the stretch wrap (40); moving the pulling clamp (32) from an initial position around a free end (22) of the elongate, flexible component (24) wound on the spool (26); gripping a starting end (42) of the stretch wrap (40) with the pulling clamp (32); moving the pulling clamp (32) and the starting end (42) of the stretch wrap (40) back to the initial position with the stretch wrap (40) disposed between the free end (22) of the elongate, flexible component (24) and outermost windings of the elongate, flexible component (24); moving the pulling clamp (32) in a downward direction so as to pinch the stretch wrap (40) within a nip defined between the outermost windings of the elongate, flexible component (24) and the free end (22) of the elongate, flexible component (24); and cutting the free end (22) of the elongate, flexible component (24) and wrapping the stretch wrap (40) around the outermost windings of the elongate, flexible component (24) until the free end (22) of the elongate, flexible component (24) is secured by the stretch wrap (40).

17. The method of claim 16, wherein the spooling machine (10) comprises two spooling heads (20) and a transverse rail (12) and wherein the stretch wrap applicator (30) is configured for and operable for moving in a transverse direction along the rail (12) relative to the spooling heads (20).

18. The method of claim 16, wherein the stretch wrap applicator (30) is configured for and operable for moving between a first spooling head (20) of the spooling machine (10) and a second spooling head (20) of the spooling machine (10) subsequent to securing the free end (22) of the elongate, flexible component (24) wound on a spool (26) of the first spooling head (20).

19. The method of claim 16, wherein moving the pulling clamp (32) in a downward direction comprises mounting the pulling clamp (32) on an angled rail (36) that is movably attached to a housing (34) with a predetermined angle such that the pulling clamp (32) and a starting end (42) of the stretch wrap (40) are moved in a generally tangential direction relative to an outer periphery of the elongate, flexible component (24) wound on the spool (26).

20. The method of claim 16, further comprising releasing the starting end (42) of the stretch wrap (40) in contact with at least a portion of the outermost windings of the elongate, flexible component (24) wound on the spool (26) so that the stretch wrap (40) disposed between the outermost windings of the elongate, flexible component (24) and the free end (22) of the elongate flexible component (24) is wrapped around the spool (26) as the remaining length of the elongate, flexible component (24) is wound onto the spool (26).