Apparatus for the reinforcement of lengths of coil wire

The disclosure embraces an apparatus for reinforcing segments or selected lengths of wire such as that used in electric coils by continuously forming a desired number of loops of the wire and then twisting the formed loops together at their midpoint to reinforce the tensile strength of the wire product; the apparatus provides means for forming the loops such as at a point upstream of a coil winding machine and a twisting device for engaging the thus formed loops and twisting them about an axis to form a reinforced length of wire which is then fed to the coil winding machine.

BACKGROUND AND BRIEF DESCRIPTION OF THE INVENTION 
The present invention relates to an apparatus for reinforcing sections of 
coil wire by forming lengths of the wire into loops and then twisting the 
loops together. 
In the manufacture of electric coils, where wire is wrapped around a core 
on automatic coil winding machines, it sometimes occurs that, where very 
fine wire is being employed, the wire breaks and fouls the elements of the 
coil winding machine. Accordingly, it is desirable to reinforce certain 
lengths of wire before it is fed to the automatic coil winding machine to 
minimize the occurrence of such stoppages. Also, certain lengths of the 
wire should be reinforced where they will be subjected to tension when 
placed in use, such as the connecting leads to the electric coil. 
In a known arrangement for reinforcing such wires, hooks have been employed 
which are moved into the path of the wire and then rotated in and out of 
the plane or path of the wire to form the loop. With such an arrangement, 
the wire is subjected to tension when the hooks first move into the path 
of the wire to grip the wire and then during the formation of each loop 
when the hooks are rotated across the path of the wire. Thus, upon each 
movement of the hooks, the wire is seized again and accelerated which 
movements, in the case of very thin winding wires, creates strain on the 
wire which can lead to frequent breaks or undesirable drawing of the wire. 
The present invention has for its object the provision of an apparatus for 
reinforcing a desired section of wire which employs wire transporting 
means that remains engaged with the wire throughout the period during 
which the reinforcing process is being effected. Also, the apparatus of 
the present invention will be capable of handling even very fine wire so 
that the occurrence of breaks will be minimized, if not eliminated. 
In a preferred embodiment, the apparatus of the present invention provides 
a wire transport means in the form of an eye or ring member which is 
guided around a closed path which encompasses a pair of guide means or 
posts of special construction which support the loops formed by the ring 
member during its travel. With such an arrangement, the wire transport 
means remains constantly in engagement with the wire and, therefore, may 
execute a continuous movement in the formation of a wire loops. According 
to one feature of the present invention, means are provided for 
disengaging the ring member of the wire transport means from contact with 
the wire where reinforcement of the lengths of wire passing through the 
apparatus is not required. 
According to another feature of the present invention, the loop forming 
path of travel of the wire transport means is arranged such that the wire 
loops are formed without imparting any twist to the wire which could 
undesirably reduce the tensile strength of the wire. 
In a preferred embodiment of the present invention, means are provided for 
forming loops of different lengths, as desired, without interfering with 
the loop forming apparatus for the subsequent twisting operation. Also, 
the twisting means of the present invention are adjustable relative to the 
formed loops so that the twist may be inserted at approximately the 
midpoint of the loops and self-compensating means are provided for 
centering the twisting means whenever a different loop length is being 
employed. 
The foregoing and other advantages of the present invention will become 
more apparent as consideration is given to the following detailed 
description and accompanying drawings, in which:

DETAILED DESCRIPTION OF THE INVENTION 
Referring now to the drawings wherein like numerals designate corresponding 
parts throughout the several views, there is shown in FIGS. 1 and 2 the 
relative disposition of various parts of the present invention. When 
installed, the apparatus is placed upstream of a coil winding machine 
which is fed with a wire 2 coming from a delivery spool (not shown) and 
which is passed over a roller 4, underneath frame 10 to a roller 6 from 
which the wire is fed to the coil winding machine. Between rollers 4 and 
6, the wire extends along a straight path indicated at 8. 
The frame 10 which is only schematically illustrated extends generally 
parallel to the path 8 of the wire and has track means in the form of two 
guide rails 12 mounted thereon extending generally parallel to the path 8 
but spaced a vertical distance therefrom as shown in FIG. 2. Mounted on 
the dual guide rails 12 is the wire transport means of the present 
invention which includes a bed 14 which is slidable along the rails 12. 
Pivotably mounted on the bed 14 is a platform 18 which is rigidly secured 
to a shaft 20 which passes through the bed 14 as shown in FIG. 2. The 
other end of the shaft 20 is fixed in a guide rod 16. The shaft 20 is 
rotatable in the bed 14 so that pivoting of the guide rod 16 will effect a 
corresponding rotation of the platform 18. On the platform 18, a mounting 
arm 22 is pivotally secured as by a pin 24. Mounting arm 22 may be in the 
form of a U-shaped bracket having dependent flanges through which the pin 
24 extends. The top surface of the mounting arm 22 carries the ring member 
26 through which the wire 2 passes. As will be described in more detail 
hereinafter, the pivotal mounting of the mounting arm 22 and thus the ring 
member 26 is provided so that when the apparatus is not being employed to 
form loops, the mounting arm and ring member 26 can be pivoted to move the 
ring member out of engagement with the wire 2 which is being passed 
rapidly past frame 10 to the coil winding machine. 
Referring to FIG. 2, on frame 10, vertically above the guide rails 12, 
there are mounted a large pulley 28 and a smaller pulley 30 with an 
endless belt or chain 32 looped about the pulleys 28 and 30 whereby the 
belt 32 will rotate in a horizontal plane which extends generally parallel 
to the path 8 of the wire 2. The guide rod 16 is pivotally connected 
through coupling 34 to the belt or chain 32. An electric motor 38 provides 
power through a reduction gear 40 to the pulley 28 through a belt 36 in 
engagement therewith. As shown in FIG. 2, the mounting arm 22 and thus the 
ring member 26 are in operative engagement with the wire 2. Referring to 
FIG. 3, as previously mentioned, mounting arm 22 and the ring member 26 
are pivotably mounted so as to be movable from a rest position in which 
the ring member 26 is disengaged from the wire 2. The pivoting of the 
mounting arm 22 into the disengaged position is accomplished by movement 
of an operating rod 46 which moves a lug 48 into engagement with a stop 
member carried on the mounting arm 22 as illustrated in FIG. 3. When the 
rod 46 is moved in a direction opposite to the arrow 50, for example, in 
the direction of arrow 52 as shown in FIG. 2, the spring means 44 will 
return the mounting arm and the associated ring member 26 to the wire 
engaging position. 
Referring now to FIG. 2, the guide means of the present invention are 
illustrated at 54 and 56, both being located adjacent to the wire path 8 
and spaced vertically beneath the two pulleys 28 and 30, respectively. 
Each of the posts 54 and 56 are mounted on the ends of pistons carried in 
cylinders 58 and 60, respectively, which may be air-actuated through hoses 
62 and 64. With this arrangement, the posts 54 and 56 may be moved to 
intercept the path 8 and easily maintained in an adjusted position. 
Cylinders 58 and 60 are each mounted on pivotable levers 66 and 68, 
respectively (FIG. 1), and stops 74 and 76 are provided adjacent to each 
of the levers to restrain swinging movement thereof of the cylinders away 
from each other. Normally, the tension springs 70 and 72 operate to 
maintain the levers 66 and 68 in contact with the stops 74 and 76, 
respectively. Locking means in the form of levers 82 and 84 are provided 
opposite the stops 74 and 76, respectively, to prevent pivoting of the 
levers 66 and 68 away from the stops during the twisting operation to be 
described hereinafter. The levers 82 and 84, are, respectively, locked in 
position by locking cylinders 78 and 80 which may be operated by air hoses 
86 and 88. 
As shown in FIG. 2, cylinder 58 and its associated post 54 are mounted 
through a shaft 83 on translating means in the form of a slide carriage 85 
which, in turn, is mounted on a threaded shaft 98 which extends parallel 
to the wire path 8. The threaded shaft 98 may be suitably rotatably 
mounted on the frame 10 as is threaded shaft 102 which is provided with a 
hand crank 90. A large gear 94 is secured on shaft 102 to cooperate with a 
small gear 96 fixed on shaft 98 whereby rotation of shaft 102 will effect 
rotation of shaft 98 to effect linear translation of the slide carriage 85 
in the direction of arrows 100 depending on the direction of rotation of 
the hand crank 90. 
A twisting means 104 is also mounted on threaded shaft 102 by a piston rod 
110 which fits into a cylinder 108 to provide a vertical adjustment of the 
carrier 106 in the direction of arrow 112. Carrier 106 is U-shaped and 
rotatably supports twisting wheels 114 and 116 therein. A rod 120 extends 
between the twisting wheels 114 and 116 and provides support for a 
twisting needle 122. The twisting needle 122 carries a fixed bar 123 
which, at its ends adjacent the twisting wheels 114 and 116, is provided 
with bores for receiving spreader pins 126 and 128. The spreader pins 126 
and 128 are frictionally held in the bores formed in the bar 123 so that 
they can be retracted in the direction of arrow 130 prior to the 
initiation of the twisting operation. 
With cylinder 60 and its associated post 56 fixed against horizontal 
movement, the translating means described above for cylinder 58 and its 
associated post 54 and the twisting means 104 will assure that for every 
horizontal movement of the post 54, the twisting means 104 will assume a 
position halfway between the adjusted distance between the posts 54 and 
56. 
Referring now to FIG. 4, it will be seen that the twisting wheel 114, which 
is identical to twisting wheel 116, is provided with a radial slit 118 
which can be aligned with the twisting needle 122 by adjustment of a drive 
wheel 124 which may be driven by any suitable means such as a small 
electric motor or belt, the details of which are not illustrated as they 
are conventional. 
The operation of the apparatus will now be described. 
In FIG. 1, the ring member 26 is illustrated in its starting or rest 
position and, as can be seen from FIG. 2, the ring member lies in a plane 
that extends substantially parallel to the wire path 8 and is resiliently 
held in this position by the spring 44. The feed of the wire 2 to the coil 
winding machine upstream of roller 6 is stopped while feed of the wire 2 
from the supply spool upstream of roller 4 is permitted. Motor 38 is then 
actuated to commence the loop forming step. As shown in FIG. 5, the bed 14 
and platform 18 are moved along the tracks 12 by virtue of the connection 
of rod 16 to the belt 32. However, platform 18 is pivoted about the axis 
of shaft 20 relative to the bed 14 as it travels its predetermined route 
defined by the path of the belt 32 and the tracks 12. It should be 
understood that FIG. 5 is a bottom view so that the posts 54 and 56 are 
only schematically illustrated while the associated translating means and 
twisting means 104 are deleted for clarity. However, it will be apparent 
that as ring member 26 is moved from the position of FIGS. 1 and 2 to the 
position illustrated in FIG. 5, a loop 134 will commence to be formed by 
virtue of the pivoting movement of the ring member 26 relative to the wire 
path 8. Continued movement of the ring member 26 to a position on the 
opposite side of path 8 will result in the formation of a bend around post 
56 by virtue of the interception of post 56 with the wire 2 as illustrated 
in FIG. 7. From FIG. 7, it will be seen that the ring member 26 has a 
relieved sector 138 of about 90.degree. which extends through a wall of 
mounting arm 22, thus providing a clearance for the top of posts 56 and 
54. In order to place the loops as tightly as possible around the posts 54 
and 56, the radius between the shaft 20 and the ring member 26 must be 
dimensioned properly to provide the juxtaposition of the ring member 26 to 
the post 56 as shown in FIG. 7 which will also apply to the post 54. Also, 
the distance between the posts and the radius of the respective pulleys 28 
and 30 must also be properly dimensioned as is the radius of the ring 
member 26 itself. 
FIG. 6 shows the ring member position prior to the formation of a second 
loop with the first loop having already been formed between the posts 54 
and 56 providing an opening 136 through which the spreading pins 126 and 
128 protrude to maintain a separation through which the twisting needle 
122 can easily be inserted. The number of traversals of the ring member 
about the path as described and illustrated will correspond to the number 
of loops formed extending between the posts 54 and 56. 
After the desired number of loops have been formed which may be counted by 
a suitable electronic counter adapted to read the rotations, for example, 
of one of the pulleys 28 or 30, the bed 14 and, thus, the ring member 26 
are returned to the starting position illustration in FIGS. 1 and 2 and 
the motor 38 is deactivated. Then, as shown in FIG. 2, the twisting needle 
is inserted into the opening maintained by the spreading pins 126 and 128 
by expansion of the piston and cylinders 108 and 110. The spreading pins 
126 and 128 may then be manually retracted by pushing them into the bar 
123. Next, the locking cylinders 78 and 80 are released whereby the posts 
54 and 56 are free to pivot on levers 66 and 68 towards each other against 
the force of the springs 78 and 72, respectively. The twisting wheels 114 
and 116 are now rotated about the wire path 8 either manually or by a 
suitable electronic motor operating through the drive wheel or gear 124 
(FIG. 4) whereby the tensioned loops of wire 2 are twisted by the twisting 
needle 122 between the posts 54 and 56. The contraction of the loops of 
wire resulting from the twisting is balanced by virtue of the permitted 
movement of the posts 54 and 56 towards the twisting needle 122, but 
controlled by the tension in the springs 70 and 72 to keep the loops 
relatively taught. 
Upon completion of the twisting process as described above, the twisting 
means 104 as well as the posts 54 and 56 are retracted from the wire path 
8 and thereby disengaged from the twisted loops. Of course, the twisted 
loops maintain their twisted configuration due to the fact that it is wire 
that is being operated on which retains its deformed configuration, as is 
well known. The feed to the coil winding machine is then actuated and the 
reinforced wire section consisting of the intertwisted loops is fed past 
frame 10 to the coil winding machine for completion of the electric coil 
manufacturing process. As previously noted, the length of the twisted loop 
section may be selected by adjustment of the distance between the posts 54 
and 56 which is effected by rotation of the hand crank 90. 
Having described the preferred embodiment of the invention, it will be 
apparent that various modifications may be made therein by those skilled 
in the art which do not depart from the spirit and scope of the present 
invention as defined in the appended claims.