Method and apparatus for packaging wire in a storage container

A container includes an outer box, and a polygonal liner located within the outer box. The polygonal liner has a plurality of vertical walls. A continuous length of wire is located within the polygonal liner and forms a plurality of layers. Each of the layers is comprised of a series of wire loops arrayed polygonally along the vertical walls of the polygonal liner.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to packaging wire, such as welding wire, into a bulk storage container. Example bulk storage containers include drums, boxes and the like.

Description of Related Art

It is known to package a continuous length of welding wire in a large container. The wire is formed into a series of loops that are arranged in a circular pattern within the container to form layers of wire. Layer upon layer are added until the container is full, which can require several hundred pounds of wire. The layers of wire, each formed by a series of loops, have a cylindrical shape within the container. If the container is also cylindrical, then each individual loop and layer of wire can be laid close to the container walls. Some containers are square-shaped and have an octagonal liner. In such cases, the layers of wire, which together form a cylindrical shape, do not sit as closely to the inner walls of the container as compared to a cylindrical container. The gaps between the octagonal liner and the wire loops can lead to shifting or settling of the wire within the container during shipment. Wire settling is generally undesirable as it requires the container to be taller than necessary (due to an initial lower density packing of the wire), and can result in tangling of the wire as it is payed out from the container, such as during an automatic or semi-automatic welding operation.

BRIEF SUMMARY OF THE INVENTION

The following summary presents a simplified summary in order to provide a basic understanding of some aspects of the devices, systems and/or methods discussed herein. This summary is not an extensive overview of the devices, systems and/or methods discussed herein. It is not intended to identify critical elements or to delineate the scope of such devices, systems and/or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with one aspect of the present invention, provided is a container. The container includes an outer box, and a polygonal liner located within the outer box. The polygonal liner has a plurality of vertical walls. A continuous length of wire is located within the polygonal liner and forms a plurality of layers. Each of the layers is comprised of a series of wire loops arrayed polygonally along the vertical walls of the polygonal liner.

In accordance with another aspect of the present invention, provided is a container. The container includes a rectangular box, and at least one polygonal liner located within the rectangular box and forming a plurality of vertical walls arranged in a polygonal shape. A continuous length of wire is located within the box and forms a plurality of layers. Each of the layers is comprised of a series of wire loops arrayed polygonally along the vertical walls.

In accordance with another aspect of the present invention, provided is a wire coiling apparatus. The wire coiling apparatus includes a rotatable wire laying head for forming a series of wire loops from a continuous length of wire. An X-Y table is configured to move in linear X-Y directions beneath the rotatable wire laying head while the series of wire loops are being formed such that the series of wire loops are arrayed polygonally within a storage container supported by the X-Y table due to the linear X-Y movement of the X-Y table.

In accordance with another aspect of the present invention, provided is a method of packaging a wire coil. The method includes providing a coiling machine. The coiling machine includes a rotatable wire laying head for forming a series of wire loops from a continuous length of wire. The coiling machine also includes an X-Y positioner configured to move in linear X-Y directions while the series of wire loops are being formed. A storage box having polygonal interior walls is placed onto the coiling machine. The series of wire loops are formed within the storage box while simultaneously moving the storage box in the linear X-Y directions by the X-Y positioner such that the series of wire loops are arrayed polygonally inside of the polygonal interior walls of the storage box.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to the bulk packaging of wire, such as welding wire. The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It is to be appreciated that the various drawings are not necessarily drawn to scale from one figure to another nor inside a given figure, and in particular that the size of the components are arbitrarily drawn for facilitating the understanding of the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention can be practiced without these specific details. Additionally, other embodiments of the invention are possible and the invention is capable of being practiced and carried out in ways other than as described. The terminology and phraseology used in describing the invention is employed for the purpose of promoting an understanding of the invention and should not be taken as limiting.

As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. Any disjunctive word or phrase presenting two or more alternative terms, whether in the description of embodiments, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” should be understood to include the possibilities of “A” or “B” or “A and B.”

FIG. 1shows a storage container C in the form of a rectangular box, in particular a square-shaped box10. The box can be formed from cardboard or a material having similar structural characteristics. The box10has outer side walls12,14,16and18that define four corners. To support a coil20of wire within the box10, a polygonal liner, such as an octagonal liner22is located within the outer box10. The liner22can also be made from cardboard or a similar material. The liner22has a plurality of vertically-extending walls that are either placed against the inner walls of the box10or extend diagonally across the inner corners of the box. The diagonal walls of the liner22at the corners of the box10form triangular corner cavities that can be filled with reinforcing elements24,26,28,30. Rather than including a single liner, the storage container C could include multiple liner members (e.g., triangular corner inserts) that together with the walls of the box form the polygonal shape of the interior of the storage container.

The coil20of wire has a generally polygonal (e.g., octagonal) cross-sectional shape, to match the shape of the liner22. Conventional wire containers that utilize an octagonal liner hold a coil of wire that is cylindrically-shaped. The difference in shapes between the cylindrical coil and octagonal liner results in gaps between the coil and the walls of the liner, and can lead to wire settling during shipment. When the wire settles, the likelihood that it will tangle when payed out from the container increases. The octagonal coil20inFIG. 1has fewer gaps between the coil and the walls of the liner22, as compared to a conventional cylindrical coil. Thus, the octagonal coil20is less likely to experience settling within the container C, or settle to a lesser degree, than a conventional cylindrical coil.

As will be explained below, the coil20is formed by a continuous length of wire arranged in a plurality of layers. Each of the layers is comprised of a series of circular loops of wire. The diameter of each loop is slightly smaller than the wall-to-wall width of the liner22(e.g., approximately 15% less than the wall-to-wall width of the liner). The center of each loop is radially offset from the axis of the box10and liner22, towards the walls of the liner. The series of wire loops that form the layers of wire are arrayed polygonally (e.g., in a rectangle, octagon, dodecagon, etc.) along the vertical walls of the liner22, to match the shape of the liner. The polygonal array of wire loops has straight sections along the center portions of the liner walls, and curved or radiused vertices. As the layers of wire formed by each series of polygonally-arrayed loops are built up, layer upon layer, the coil of wire assumes the shape of a polygonal (e.g., octagonal) prism having a central opening and radiused vertices. The loops of wire are laid in a polygonal array by moving the storage container C and/or a rotating wire laying head in linear X-Y directions while the loops are formed by the laying head of a wire coiling apparatus.

FIG. 2shows portions of an example wire coiling apparatus32. A continuous length of welding wire34is drawn from a manufacturing process (not shown). The welding wire34is drawn by a capstan36driven by a motor38. A series of dancer rollers40maintain tension on the wire. The welding wire34is wrapped approximately 270° about the capstan36. This provides proper friction and drive capacity to draw the welding wire34across the dancer rollers40.

From the capstan34, the welding wire is fed into a rotatable wire laying head42. The laying head42can be a generally cylindrical tube having an opening at the bottom or along the cylinder adjacent to the bottom. The welding wire34passes from the capstan36to the interior of the laying head42. The welding wire34extends through the tube and out the opening in the laying head42, whereupon it is placed into the storage container C. The laying head42is suspended from an upper portion of the coiling apparatus32for rotation about a generally vertical axis A.

The laying head42extends into the storage container C and rotates about the axis A, which is generally parallel to an axis B of the storage container. The wire being fed into the laying head42by the capstan34is fed at a rotational velocity different than the rotational velocity of the laying head. The ratio between the rotational velocity of the laying head42and the rotational velocity of the capstan34determines the loop size diameter of the wire loops within the storage container C. A motor44drives the laying head42, such as via a drive belt. A controller46controls the speed of the capstan and laying head motors38,44and allows for adjustments of the ratio between the speed of the two motors, to thereby adjust the diameter of the wire loops that form the polygonal coil. Example wire loop diameters are approximately 14-17 inches, however diameters outside of this range can be provided if desired.

As the wire34is laid within the storage container C, sensors check the wire height and the storage container is lowered by the controller46. As the storage container moves downward, the laying head42continues to rotate, thus filling storage container C to its capacity. The storage container C is supported on an L-shaped beam47that is vertically-movable along a guide track48(e.g., in the Z-direction shown by double headed arrow). A cylinder and piston assembly50and/or an actuator such as a ball screw actuator is attached to the L-shaped beam and a frame of the coiling apparatus32and allows for the controlled descent of the storage container C as it is filled with wire. It is to be appreciated that laying head42need not move in the vertical direction because the storage container C moves downward, away from the laying head, as it is filled.

The coiling apparatus32includes an X-Y table52or a similar X-Y positioner, to which the storage container C is mounted. The X-Y table52can include clips54or other clamping devices for attaching the storage container C securely to the X-Y table. The X-Y table52moves the storage container C in the X and Y directions (e.g., within a generally horizontal plane) beneath the laying head42while the series of wire loops are being formed. The Y-direction is shown schematically by a horizontal double headed arrow inFIG. 2, and the X-direction would be perpendicular to the Y-direction and the Z-direction (e.g., into and out of the plane of the figure). The X-Y table52or positioner can employ linear actuators, such as belt-driven actuators, ball or lead screw actuators, rack-and-pinion actuators, pneumatic or hydraulic actuators, and the like. The movement of the X-Y table52during operation of the laying head42is controlled so that the series of wire loops that form layers of the coil20are arrayed polygonally within the storage container C, along the polygonal walls of the liner. In particular, the loops are arrayed in an octagonal pattern established by the X-Y table52moving the container C beneath the laying head42. The movement of the X-Y table52can be controlled by the controller46. Alternatively, the laying head42can be moved in X-Y directions while forming the wire loops. If desired, the X-Y table52can provide for variable speed movements in the X and Y directions, to allow the wire loops to be arrayed along curved lines. In certain embodiments, the wire coiling apparatus32can include a turntable that allows the container C to be rotated around its axis B, in addition to moving in the X and Y directions. The turntable can allow for the series of loops to be laid in a circular pattern if desired.

The controller46can include an electronic controller having one or more processors. For example, the controller46can include one or more of a microprocessor, a microcontroller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), discrete logic circuitry, or the like. The controller46can further include memory and may store program instructions that cause the controller to provide the functionality ascribed to it herein. The memory may include one or more volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), flash memory, or the like. The controller46can further include one or more analog-to-digital (A/D) converters for processing various analog inputs to the controller.

FIG. 3shows the result of placing wire loops in a circular array within an octagonal liner22, andFIG. 4schematically shows an example circular array of the wire loops. The welding wire34is looped within the liner22by rotation of the laying head about its axis A. The rotation of the laying head is shown by arrow56. The axis A of the laying head is radially offset from the axis B of the storage container and liner22. The storage container is rotated counterclockwise a fraction of one revolution (e.g., one or two degrees) while the laying head generates the wire loops. Rotating the storage container while generating the wire loops results in the creation of the circular array of loops. It can be seen inFIG. 3that some of the loops in the circular array touch the sides of the liner22, whereas other do not. Gaps exist between the loops and liner wall in the lower left portion ofFIG. 3. It is such gaps that allow the wire to settle during shipment of the container of wire, which can result in tangling of the wire as it is payed out of the container and need for a taller container.

FIG. 5shows example linear movements of the storage container C in the X and Y directions beneath the wire laying head while the series of wire loops are formed.FIG. 6shows an example polygonal array of the wire loops, such as would be found in a layer of loops in the container C. The axis B of the storage container C can be offset from the rotational axis A of the laying head so that the loops of wire in the polygonal array are not centered in the storage container, but are offset toward the vertical walls of the octagonal liner22. The amount of offset between the axis B of the storage container C and the rotational axis A of the laying head can depend on the diameter of the wire loops, and, thus, the rotational velocities of the capstan and laying head. Smaller wire loops are formed using a greater offset between the axis B of the storage container C and the rotational axis A of the laying head, so that the loops are placed along the walls of the liner22. When larger wire loops are formed, the offset between the axis B of the storage container C and the rotational axis A of the laying head is reduced. The offset between axes A and B can be controlled by the controller46(FIG. 2), based on the desired loop diameter. To minimize the gaps between the loops of wire and the inner walls of the liner22, the loops can be placed within the liner so that they each touch at least one of the walls of the octagonal liner22at a tangent. This can be achieved by properly offsetting the axis B of the storage container C from the rotational axis A of the laying head, and moving the storage container in linear X-Y directions while forming the loops of wire. As the storage container C is moved while the wire loops are formed, the offset between the axis B of the storage container C and the rotational axis A of the laying head will change, for example increase and decrease, as the container is moved in an octagonal pattern as indicated by the arrows inFIG. 5. An example offset between the axis B of the storage container C and the rotational axis A of the laying head is one-half the difference between the interior width of the liner22(wall-to-wall distance between opposed vertical walls) and the diameter of the wire loop when the axis B of the storage container and the rotational axis A of the laying head are aligned with the centers of the opposed vertical walls of the liner. In certain embodiments, the loop size can be adjusted while the container C is being filled, so that some layers of wire are formed by loops of a first diameter and other layers of wire are formed by loops of a second diameter, different from the first diameter. In such embodiments, the offset between the axis B of the storage container C and the rotational axis A of the laying head can be adjusted and controlled while the storage container is being filled to accommodate the different diameter loops of wire.

As indicated by the arrows inFIG. 5, the storage container C is moved by the X-Y table52(FIG. 2) or positioner in an octagonal pattern, so that the wire loops are laid in an octagonal array that matches the shape liner22. The pattern and direction of the arrows inFIG. 5is exemplary and the storage container C could be moved in opposite directions (e.g., in a clockwise octagonal pattern) and in other patterns (e.g., a square or other polygonal pattern). To array the wire loops in an octagonal pattern, the X-Y table or positioner moves the storage container C in eight different linear directions in the X-Y plane while the wire loops are formed by rotation of the laying head. The diameter of the wire loops is controlled by the rotational speed of the capstan and laying head, and the placement of the wire loops in the storage container C is controlled the movements of the X-Y table or positioner. Preferably, each wire loop touches at least one of the vertical walls of the liner22at a tangent to minimize the gaps between the coil of wire and the walls of the liner. However, some loops may not touch a wall of the liner while other loops (e.g., the majority of the loops) do. As the storage container C is moved in an octagonal pattern, the axis B of the storage container travels around the rotational axis A of the laying head in X-Y directions in the octagonal pattern, so that the wire loops are laid against the vertical walls of the liner22. In certain embodiments the storage container C can also be rotated by a turntable while the wire loops are formed in the container and such rotation can occur with or without simultaneously moving the storage container in the X and/or Y directions. In other embodiments, the X-Y table or positioner moves the storage container C in the linear X-Y directions beneath the rotatable wire laying head while the series of wire loops are being formed without rotating the storage container about the axis B of the storage container. In certain embodiments, the laying head can be moved in the X and Y directions to lay the wire loops in a desired polygonal pattern. Alternatively, the laying head can be configured for movement in one of the X and Y directions and the wire coiling apparatus can move the storage container C in the other of the X and Y directions, so that the laying head and storage container move together while the wire loops are formed, to array the loops polygonally.

Comparing the circular array of wire loops shown inFIG. 4and the octagonal array of wire loops shown inFIG. 6, it can be seen that the octagonal array of wire loops has straight sections S along the center portions of the liner22walls, and curved or radiused vertices R. The radius of the vertices R is large so that the octagonal shape of the array of wire loops has eight short, straight sides S connected by sweeping curves R of about the same length as the short, straight sides. The relative lengths of the straight sections S and the curved vertices R formed by the polygonal array of wire loops is determined by the interior wall-to-wall width of the liner22and the diameter of the wire loops. As the diameter of the loops is made smaller, the length of the straight sections S of the polygonal array increases and the length of the curved vertices R connecting the straight sections decreases. As the diameter of the loops increases, the length of the straight sections S of the polygonal array decreases and the length of the curved vertices R connecting the straight sections increases.