Coil making apparatus and method

An apparatus (1) and a method for coiling a cable (2) or a wire into a coil (3) having a plurality of turns (3a) and two free ends (4, 5) formed by a leading end (4) and a trailing end (5) of said cable are disclosed. The apparatus comprises a rotatable coil former (6) around which a cable is coiled; means (9) to measure the length of the coiled cable (2) or wire; first holding means (10) positioned on said coil former (6) for holding the leading end (4) of the cable, second holding means (12), separate from said coil former (6) for receiving and holding the leading end (4) of the cable (2), which are movable. Cutting means (14) for cutting the coiled cable to provide a trailing end (5) of the cable are also provided. The apparatus further comprises means (7) to adjust the diameter (D1, D2) of the coil former (6) and control means (18) to set said adjusting means (7) of the diameter of the coil former (6), to provide the required length of the cable and the required length of the said free ends (4, 5) of the coiled cable.

This application is the US national phase application of international application number PCT/EP2014/059671, filed 12 May 2014, which designates the US and the contents of which are hereby incorporated by reference as if set forth in their entirety.

FIELD OF THE INVENTION

The present invention relates to a coil making apparatus and method, in particular, to an apparatus and a method for coiling a cable or wire or similar conducting devices, to provide a coil having two free ends that can be processed.

BACKGROUND ART

It is known to wind cables or wires into coils for further storing, shipping or further processing. It is known to make coils by winding the cable or wire into a drum-like cavity of a non-rotating winding apparatus, as disclosed e.g. by DE 42 35 007; this method is not suitable for preparing coils with ends ready for further processing, also because it is not possible to control the radius of curvature of the cable. The radius of curvature can be controlled by using a coil forming apparatus where the cable is wound around a coil former; once the coil has been formed around the forming nucleus, the former's diameter is decreased to allow safe removal of the coil.

In fact, one problem faced by the known methods and apparatuses is to provide a required length for the two cable ends for further processing of the cable at its two ends. U.S. Pat. No. 6,948,675 discloses an apparatus for making coils from a length of cable (namely fiber optic cable); the apparatus has a coil former and two grippers for the two ends of the cable, the grippers are movable by means of relevant carriages on rails, so as to adjust the lengths of the two ends to be the same or almost the same. In this embodiment, the two grippers hold the two ends of the cable and are aligned to each other during the final step of adjusting the length of the free ends.

WO2010/001342 discloses an apparatus for coiling pieces of cable or of wire. The cable is first cut into the desired length and then wound around a coil former; the coil former has a diameter that can be modified and controlled. According to WO'342, the diameter of the coil former is changed during the winding of the cable in order to have a final free end (trailing end) of the coil having the required length, substantially identical to the first free end (leading end) of the coil.

Actually, changing the diameter of the coil during the forming of the coil is a step very difficult to achieve, especially once a couple of windings have been provided on the coil former. Another problem of this document is that the cable (or wire) has to be cut into the desired length in advance; a cut cable may be difficult to handle, especially if the cable is longer than a few meters, e.g. longer than 3-4 meters.

It is an aim of the present invention to solve the above problems and to provide an apparatus and a process in which a continuous cable is fed to the coil-forming machine, is coiled and can be cut into the desired length with great accuracy, and wherein the two cable's ends protrude from the same side of the coil and have a predetermined length, and preferably the same length.

SUMMARY OF THE INVENTION

The above stated aim is reached by means of the apparatus and process of the present invention. A further object of the invention is a coil (coiled cable). The coil according to the invention is obtainable by the method for coiling a cable according to the invention.

The apparatus of the invention comprises a rotatable coil former around which a cable is coiled; means to measure the length of the coiled cable or wire; first holding means on the rotating part of the coil former for holding the leading end of the cable, second holding means, separate from said coiler, for receiving the leading end of the cable, said second holding means being movable, cutting means for cutting the coiled cable to provide a trailing end of the cable.

The apparatus further comprises means to adjust the diameter of the coil former and control means to set said adjusting means of the diameter of the coil former, to provide the required length of the cable and the required length of the said free ends of the coiled cable.

According to the present invention, the cable is wound a pre-set number of times around a coil former having a first diameter to provide a first coil having a pre-set number of windings, then the cable is cut to provide two free ends of the coil: said free ends have a required length and are spaced from each other by a required distance. Length and spacing distance of the free ends of the coil are chosen as a function of the machine that will carry out the further processing of said ends of the coil; known exemplary further processing include stripping of the cable's ends, adding metal connectors and over-moulding of the plastic to form the final plug (male or/and female). In a preferred embodiment, the cutting means and the second holding means are spaced from the coil by a distance, or moved to be spaced from the coil by a distance, that is identical or substantially identical to the required length for the free ends of the coil.

The length of the cable is measured during or after winding the cable on the coil former and before cutting it; the length of the cable is a function of the number of windings of the coil, of the diameter of the coil former and of the diameter of the cable. An example of coil is shown inFIG. 7. There are provided 5 windings along the width of the coil. This means that at each turn of the coil former, the diameter of the “core” around which the cable is coiled, is increased by the diameter of the previous windings. The diameter of the cable is not constant. The diameter can change within a range that is set by the cable producer. For example, a cable that has a formal, i.e. nominal, diameter of 10 mm may easily reach a diameter of about 10.4 mm.

The increased cable diameter results in an increase of the length of the cable, after an identical number of windings (turns); as an example, for a cable that is 20 meters long, or more, a difference in length of 30-50 cm can easily be reached for the wound cable. If the length differs from the required one, e.g. it is shorter or longer, for example by a value that is greater than an acceptable value that was previously set, the diameter of the coil former is modified according to the result obtained, after the coil has been removed from the coil former, i.e. before another coil is formed.

Thus, the diameter of the coil is increased or decreased depending on the length of the piece of cable that has been coiled; the modification of the coiler diameter is carried out at the end of the coiling step for which the cable length has been measured. In other words, the adjustment will be effective on the coiling process that follows the process where the cable length has been measured.

Advantageously, the apparatus and the method according to the invention, the adjustment of the diameter of the coil former also allows to obtain the required length for the free ends of the cable.

In particular, the adjustment of the diameter allows to have the free ends of the cable in a predetermined position, with respect to the coil, thus allowing the automatic processing of the free ends for example in a cable processing device.

Further advantageous details of the invention are recited in the dependent claims.

The elements which have been mentioned above and those which are claimed and described in the following exemplary embodiments, can be combined together to provide further embodiments that fall within the scope of this invention.

The apparatus and the process are not restricted to cable-like conductors, e.g. coaxial cables, or to cables having a circular cross-section as those shown in the following description and figures.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

As shown in the figures, according to a possible embodiment of the apparatus1for coiling a cable2, or a wire, into a coil3, it comprises a rotatable coil former6around which a cable is coiled (wound) to form a plurality of turns3aand two free ends4,5, formed by a leading end4and a trailing end5of the cable2.

It has to be noted that in the following the term “free ends” is used to indicate the trailing end and leading end, in fact, the free ends of the coil are formed by a leading end of the cable and a trailing end of the cable.

The cable2intended to be coiled can be supplied, preferably continuously, in a known way from one or more reels57, or other supply means not shown in the figures.

The apparatus1further comprises means9to measure the length of the coiled cable2or wire, which are known in the art. The means9measure the length of the cable2supplied to the coil former6, and preferably the cable length passing cutting means14of the apparatus intended to provide the trailing end5of the cable2for the formation of the coil.

According to a possible embodiment, as for example shown in the attached figures measuring means9comprise a measuring wheel to easily measure the cable length. However, different position of the measuring means9can be used, provided that the distance between the cutting means and the measuring means is known and the cable length between the leading end and the trailing end provided by the cutting means can be determined.

According to different possible embodiments, the measuring means9can be also provided in correspondence of the cutting means14.

In fact, as mentioned above, the cable2is preferably supplied continuously to the coil former6and it is cut by the cutting means14of the apparatus1.

In fact, the apparatus1is further provided with cutting means14, for example comprising one or more blades, intended to cut the cable2thus forming a trailing end5thereof.

According to different possible embodiments, cutting means14can be automatically operated, such as for example by means of an actuator.

The coiling apparatus1further comprises first holding means10, preferably positioned on the coil former6, for holding the leading end4of the cable, while it is rotated on the coil former. Also in this case, different holding means, known in the art can be used, such are for example grippers allowing to engage and to release the leading end4of the cable.

The operation of the first holding means can be carried out by suitable actuator, not shown in the figures.

According to an aspect of the invention, the first holding means10are arranged in correspondence of the external diameter, i.e. the external circumference of the coil former6, and preferably at the maximum diameter (circumference) of the coil former6. The coil former comprises a lower circular flange6afor supporting the lower turns3aof the coil3and, as it will be described later, the coil former comprises a cylindrical surface on which the cable is coiled, thus providing the internal support for the coil.

The apparatus further comprises second holding means12, separate from said coil former6, for receiving and holding the leading end4of the cable2, from the first holding means10.

It has to be noted that, even if not shown in the figure, suitable transporting means, such as for example a mechanical arm can be provided to transport the leading end of the cable from the supply reel57, or from the cutting means14, or suitable support means13, to the first holding means10arranged on the coil former6.

As already mentioned in connection to the first holding means10, also the second holding means12can have in different configurations, provided that they are able to selectively hold and release the cable leading end4.

The second holding means12are movable with respect to the coil former6, preferably between at least a first position in which they are close to the first holding means10allowing the passage of the cable leading end4from the first holding means10to the second holding means12, and at least one second position where the second holding means12and thus the leading end4are arranged at distance from the coil former6. According to a possible embodiment the second holding means12are movable along a guide12a, preferable a rectilinear guide. However, different configuration of the second holding means, and of the movement thereof, can be provided.

It has to be noted that the second holding means12are moved to be spaced from the coil3(and thus from the coil former6) by a distance that is identical or substantially identical to the required length for the leading end4of the coil.

It has to be noted that, according to another possible embodiment not shown in the figures, the second holding means can be fixed and spaced from the coil by a distance identical or substantially identical to the required length for the leading end4of the coil, and suitable transferring means are used to transport the leading end4of the cable from the first holding means10to the second holding means12.

The same applies to the cutting means14of the apparatus. In fact, the cutting means14are spaced from the coil (and also form the coil former) by a distance, or moved to be spaced from the coil by a distance, that is identical or substantially identical to the required length for the trailing end5of the coil.

In other words, according to the apparatus of the invention, the position of the cutting means14and of the second holding means12are predetermined so that the required length of the free ends4,5(leading end and trailing end of the cable) are predetermined.

According to a possible embodiment, the position of the cutting means14and/or the position of the second holding means12is adjustable within a range that is L−X mm and L+X mm, wherein L is the required length of the free ends4,5of the cable and X is the variation for the required length L (see for exampleFIG. 3). In other words, the value X is a variation, and in particular an accepted variation, of the cable length L which can be set by the apparatus according to the invention. According to a possible embodiment L±X is the range within the cable length can be set.

However, as already discussed above, during the coiling of the cable around the coil former to form the turns3a, variations in the cable diameter (for example with the tolerance provided by the cable manufacturer) and also different relative positions between the coiled cable, i.e. the position of one turn with respect to another, would inevitably lead to a modification in the cable length. This problem is particular sensed if the coiled cable is very long, such as for example with cable length over 5 meters, and it considerably increases if the cable is longer than 10 meters, or about 20, or about 30 meters or even longer.

Advantageously, to obtain coils3having a required length of the cable and also the required length of the trailing end and of the leading end, which are arranged outside the coil turns, the apparatus according to the invention comprises means7to adjust the diameter D1, D2of the coil former6and control means18(schematically shown only inFIG. 1) to set said adjusting means7of the diameter of the coil former6, to provide the required length of the cable and the required length of the free ends4,5of the coiled cable.

The control means18, for example a control unit, is able to set the adjusting means7of the diameter of the coil thus providing a final coil with the required total length and also having both free ends4,5having the required length.

More in detail, the coil former6is rotated about a central axis A, which substantially correspond to the central axis A′ of the coil3formed on it. In fact, the coil former is provided with a lateral cylindrical surface on which the cable is wound to form the turns3a. According to a possible embodiment, as also shown in the figure, the adjusting means7of the diameter of the coil former modify the diameter of the cylindrical surface on which the cable is coiled.

According to preferred embodiment, as for example shown in the figures, the means7for adjusting the diameter of the coil former6comprises a plurality of coil supporting elements8forming the cylindrical surface on which the cable is coiled (see in particularFIGS. 2-6).

In other words, the supporting elements8are tangent to a cylindrical surface on which the coil3is formed and therefore the inner (internal) diameter Din of the coil corresponds to the diameter of the surface defined by the supporting elements8.

The supporting elements8are preferably radially arranged with respect to the central axis A of the coil former6and they are movable, preferably radially, to adjust the diameter of the coil former6.

Suitable moving means such as motor means34, are provided to move, preferably radially, the coil supporting elements8with respect to the central axis A′ (A) of the coil3(coil former6).

The movement of the coil supporting elements8can be obtained by a rotation or a linear movement, or by a combination of linear and rotation movements.

Advantageously, in the coiling apparatus according to the invention, the modification of the diameter of the coil former is carried out in a simple and quick way by acting on said adjusting means7of the diameter.

FIG. 2shows the coil former6with the adjusting means7in three different positions. In particular, the coil supporting elements8can be moved to form the circular (cylindrical) surface on which the cable is coiled having a first diameter D1(see central image ofFIG. 2) and of a second diameter D2(shown in the right end image ofFIG. 2), greater than the diameter D1.

It has to be noted that supporting elements8can be moved in a plurality of intermediate positions, between a maximum diameter and a minimum diameter, in order to provide a fine adjustment of the diameter of the coil former.

According to an aspect of the invention, the adjusting means7and in particular the coil supporting elements8are movable between a minimum diameter of 110 mm and a maximum diameter of 200 mm. However, different dimensions can be provided according to different configurations of the apparatus1.

Additionally, the coil supporting elements8are also movable to a diameter less than the minimum diameter on which the cable can be coiled. This diameter is used to remove the formed coil from the coil former. For example, the left-hand image ofFIG. 2shows the coil supporting elements8in a position in which the diameter Dremov is less than the minimum diameter used for coiling the cable, thus allowing the removal of the formed coil from the coil former6.

According to a preferred embodiment, the adjustment of the diameter of the coil former, in order to obtain the required cable length and also the required lengths of the free ends4,5is performed by taking into account the measured cable length of the actual formed coil and to adjust the diameter for a subsequent coil to be formed on the coil former.

In fact, according to a possible embodiment, the control means18set the adjusting means7to adjust the diameter for a subsequent coil to be formed on the coil former6on the basis of the cable's measured length of the actual processed coil compared to the required length of the cable.

By doing so, the adjustment of the diameter for subsequent coil to be formed, based on the comparison of the measured cable length with the required cable length, allows to correct length errors. The adjustment is preferably repeated for each coil, so that the subsequent coil to be coiled is formed on a diameter adjusted taking into account the length errors determined for the precedent coil.

According to an aspect of the invention, also the actual length of the free ends4,5of the cable compared to the required length of the free ends4,5of the cable can be used by the control means18to adjust the diameter.

According to an aspect to the present invention, the control means18comprises a memory portion whereby the required length of cable for the coil is memorized (stored). It has to be noted that a plurality of required lengths values can be stored on the control means according to different coil dimensions which can be produced by the apparatus1. As mentioned above, the control means18compare the cable's measured length with the required cable length, preferably stored on said memory portion.

According to a possible embodiment, also the length of the free ends4,5of the cable of the actual processed coil can be compared to the required length of the free ends4,5(which can be also stored in the memory portion of the control means18) of the coiled cable to adjust the diameter.

As for example shown in theFIGS. 3-6, the supply way (orientation) of the cable and the exit way of the cable from the coil are equal if seen on a plane perpendicular to the rotation axis A of the coil former6. In the embodiment shown in theFIGS. 3-6, the cable is supplied moving from left to right and the cable is also removed from the coil former moving from left to right.

The supply direction and the exit direction of the cable are preferably parallel, or coincident as for example in the embodiment shown in theFIGS. 3-6, wherein the leading end4engaged by the second holding means12and the trailing end cut by the cutting means14are arranged substantially, on the same rectilinear direction.

The coil3according to the invention, which can be produced by the apparatus according to the invention, and with the method according to the invention, is provided (as better shown inFIGS. 8 and 9) with a plurality of turns3aand two free ends4,5formed by a leading end4and a trailing end5of a cable2or a wire, preferably having the same exit area20.

In other words, the arrangement of the cutting means14of the cable and of the second holding means12of the apparatus1, to be substantially opposite one to another with reference to the coil former, allows the trailing end5and the leading end4of the cable2to exit the coil substantially in correspondence of the same exit area20. In other words, the leading end and the trailing end of the coil are departing from the turns3a, i.e. they are exiting the turns of the coil substantially in correspondence of the same (common) exit area20.

The term “exit area” is used herein to indicate the area in correspondence of which the leading end4and the trailing end5of the coil do not follow the coiled (rounded) shape of the turns3aand exit outside the coil.

According to a preferred aspect of the invention, the exit area20of the trailing end5and of the leading end4from the coil is arranged substantially on a radial axis R passing through the central axis A of the coil former, which substantially corresponding to the axis A′ of the coil3.

In other words, the trailing end and the leading end exit the in correspondence of the same radius departing from the central axis A of the coil former6(the control axis A′ of the coil).

As shown in the figures, the leading end4is arranged closer to the central axis A (A′), in correspondence of the internal surface (internal diameter Din) of the coil, and the trailing end is arranged in correspondence of the external surface (external diameter Dext) of the coil and they are exiting the coil in the same area20defined by a radial axis R.

It has also to be noted that trailing end5and the leading end4extend opposite one to another with respect to same exit area20from the coil.

As for example visible in theFIGS. 3-6, according to an aspect of the invention, in the apparatus1the cutting means14and the second holding means12are arranged on two opposite sides with respect to the same (common) exit area20of the trailing end5and of the leading end4from the coil3. In particular, the cutting means14and the second holding means12are arranged on two opposite side with respect to the radius passing through the exit area20.

In fact, as shown in particular inFIG. 6, the cutting means14are arranged on the left side with respect to the exit area20, and in a particular on the left side of radius passing through the exit area20, and the second holding means12are arranged on the right side with respect to the exit area20.

Additionally, the apparatus according to invention further comprises tying means15(schematically shown inFIG. 1) to provide at least one tie16on the coil3. Preferably, the tying means15are arranged to provide at least one tie16in correspondence of the same exit area20of the trailing end5and of the leading end5from the coil. In other words, the exit area20can be seen as to be defined by the tie16arranged on the coil3. In fact, the tie16keeps the turns3apacked while allowing the trailing end5and the leading end4to exit from the coil3.

The tie can be for example comprise a strip of plastic material, optionally reinforced with a metal core. However different configuration of the tie16can be provided. According to a possible embodiment, not shown in the figure the trailing end5and the leading end4can exit the coil3at two different area, preferably arranged along a semicircle part of the coil (and also of the coil former), preferably not in correspondence of two diametrically opposite points of the semicircle part, i.e. not in correspondence of the diameter of the semicircle part.

According to an advantageous aspect of the present invention, the apparatus and the relative coiling method allows to obtain coils3having a predetermined length while having the free ends4and5at required length, so that the ends can be arranged in a desired predetermined position to be processed outside the apparatus1.

In particular, the control means18can adjust the diameter of the coil former so as the required length of the free ends is obtained. Advantageously, the required length of the free ends4,5of the cable is such that the extremities4a,5aof the trailing end5and of the leading end4are arranged at the same distance D from the external surface S of the coil. The external surface of the coil can be identified by the external diameter Dext of the coil3, see for exampleFIG. 9.

As for example shown inFIG. 9, the distance D is measured between the external surface S of the coil and a plane P that is tangent to the external surface of the coil, preferably in correspondence of the exit area20of the free ends4,5from the coil. The plane P is externally spaced from the external surface S at distance D.

According to a further aspect of the invention, the required length of the free ends4,5of the cable is such that the trailing end5and the leading end4are arranged at the same lateral distance Y from a plane P′ passing through the central axis A′ of the coil (central axis A of the coil former6) and the exit area20of the free ends4,5from the coil, see for exampleFIG. 9.

The apparatus further comprises transport means11(schematically shown inFIG. 1) of the formed coil3from the coil former to the outside, preferably to another station of a processing device to which the coil apparatus1is connected.

FIG. 7shows a section, from a plane passing through the central axis A′ of the coil3, showing the turns3aformed by the coiled cable. The number of “columns” and “rows” of superimposed turns and laterally arranged turns can be varied according to different configurations.

With particular reference toFIGS. 3-6a possible embodiment of the method for coiling a cable2will be now described.

The method according to the invention for coiling a cable2or a wire into a coil3by means of an apparatus1according to the invention comprises the step of transferring the leading end4of the cable2to the first holding means10, positioned on the rotatable coil former6for holding the leading end4of the cable, seeFIG. 3. In particular a cable2is supplied from a reel57, or similar means, in a known way.

The coil former6is then rotated about the central axis A for coiling the cable2, thus forming a plurality of turns3a(seeFIG. 4). Said control means18controls the number of rotation of the cable.

Subsequently the leading end4of the cable2is transferred to the second movable holding means12, separate from the coil former6. It has to be noted that the second holding means12are moved in a position close to the first holding means in order to allow the transfer of the leading end4from the first holding means10to the second holding means12, as for example shown inFIG. 5.

According to another possible embodiment, the second holding means12can be fixed and suitable transferring means, for example a mechanical arm, can be provided to transfer the leading end4from the first holding means10to the second holding means12.

According to an aspect of the method, the second holding means12are spaced from the coil by a distance, or they are moved to be spaced from the coil by a distance, that is identical or substantially identical to the required length for the leading end4of the coil.

The second holding means12are shown in position distanced from the coil (coil former) inFIG. 6.

To provide the trailing end5of the cable, the cutting means14are operated. According to an aspect of the invention, the cutting means14are spaced from the coil, or moved to be spaced from the coil, by a distance that is identical or substantially identical to the required length for the trailing end5of the coil. The cutting means14are shown inFIG. 6distanced from the coil3(coil former6).

As mentioned above, the length of the trailing end5and of the leading end4are predetermined by the position of the cutting means14and of the second holding means12with respect to the coil3(or with respect to the coil former6).

According to a possible embodiment, the method further comprises the step of adjusting the position of the cutting means14and/or the position of the second holding means12. The position can be adjusted within a range that is L−X mm and L+X mm, wherein L is the required length of the free ends4,5of the cable and X is the variation for the required length L (seeFIG. 3).

In other words, X is the accepted length variation for the cable, and thus L±X is the range within the required length L can be set. It has to be noted that the value X can be also seen as the accepted tolerance for the cable length L.

The method according to the invention, advantageously comprises the step of adjusting the diameter of the coil former6to provide the required length of the cable and the required length of the said free ends4,5of the coiled cable. According to a preferred aspect of the invention, the diameter of the coil former6is adjusted for a subsequent coil to be formed on the coil former6on the basis of the cable's measured length of the actual processed coil compared to the required length of the cable.

More in detail the method comprises the step of continuously measuring the length of the processed cable and in particular the length of the cable passed after the cutting means14, i.e. the length of the cable between the leading end and the trailing end. By measuring the cable length and by comparing it with a required length of the cable, the length error due in particular to the variation of the diameter of the cable and due to the differences in relative positions of the turns of the coiled cable, can be determined and used to modify by the control means18the diameter of the coil former6. By doing so, the required length of the cable and the required lengths of the free ends4,5can be reached in the subsequent formed coil.

Preferably, this step is repeated for each coil to continuously adapt the coil former diameter for a subsequent coil on the basis of the length determined for the precedent coil. In fact, in the method, the step of adjusting the diameter of the coil former6for a subsequent coil to be formed on said coil former6on the basis of the cable's measured length of the actual processed coil, compared to the required length of the cable, is repeated for each coil.

As already mentioned, in connection to the apparatus1, also the actual measured length of the free ends4,5of the actual processed coil can be used to adjust the diameter of the coil former, preferably by comparing the measured length of the free ends4,5with the required length of the free ends4,5of the coiled cable.

In particular, as mentioned above, the step of adjusting the diameter of the coil former6to provide the required length of the cable and the required length of the said free ends4,5of the coiled cable, is carried out by comparing the cable's measured length with the required cable length, preferably memorized (stored) in a memory portion of the control means18.

Preferably, in the method according to the invention, in the step of adjusting the diameter of the coil former a plurality of coil supporting elements8are moved to adjust the diameter. As disclosed above in connection to the apparatus1, preferably the coil supporting elements8are moved with respect to the central axis A by rotation and/or by linear movements.

The method further comprises the step of tying the coiled cable, by suitable tying means15. At least one tie16is provided on the coil, preferably in correspondence of the same exit area20of the trailing end5and of the leading end4from the coil.

It has to be noted, that in the method according to the invention the adjustment of the diameter of the coil former also allows to obtain the required length for the free ends of the cable.

In particular, the adjustment of the diameter allows to have the free ends of the cable in a predetermined position, with respect to the coil, thus allowing the automatic processing of the free ends4,5, for example in a cable processing device.

In particular, in the method the diameter is adjusted by control means18, to obtain a coil3wherein the extremities4a,5aof the trailing end5and of the leading end4are arranged at the same distance D from the external surface S (external diameter) of the coil3, preferably in correspondence of the exit area20of the free ends of the coil. As mentioned above, the distance D is measured between the external surface S of the coil and a plane P that is tangent to the external surface of the coil, preferably in correspondence of said exit area20of the free ends4,5from the coil, and externally spaced from the external surface S at distance D.

The method also allows to obtain a coil, wherein the trailing end5and the leading end4are arranged at the same lateral distance Y from a plane P′ passing through the central axis A′ of the coil and the exit area20of the free ends4,5from the coil.

The coiling apparatus1according to the invention can be used in cables or wires processing devices wherein the formed coil, and in particular the free ends thereof can be processed.

As for example shown inFIG. 1, a cables or wires processing device50can be provided with at least one coiling apparatus1. In the shown embodiment ofFIG. 1only one apparatus1is provided, however the processing device50can be provided with two or more coiling apparatus1.

According to different embodiments, the device50can comprise at least one processing station51,52,53. Means55for retaining and moving the free ends4,5of one or more processed coil from the coiling apparatus1to the at least one processing station51,52,53, and/or between two or more processing stations51,52,53, if present, can be also provided.

Different configurations of the device50can be provided, and the at last one processing station51,52,53can be selected from at least one station52for injection moulding on at least one of said free ends4,5of the coil, preferably on both of said free ends4,5, at least one station51comprising means for applying electrical connection elements to said at least one of said free ends4,5of the coil, preferably on both of said free ends4,5, at least one station53comprising means for testing said coil, or a combination of said stations51,52,53. Additional stations, for example intend to perform other process on the cable, and in particular on one or more ends4,5of the coil3can be provided. According to a possible embodiment, the station52for injection moulding comprises at least one movable injection mould, said at least one mould being translated and/or rotated, in order to increase the number of processed cables while reducing the occupied space.

It has to be noted that support means56for the turns3aof said one or more processed coils3are provided in order to support it while one, or both ends4,5are retained and moved along the processing stations. The support means56for the coil3can comprise a movable surface, such as for example a transport support, or a transportation belt, on which the coils3are arranged. The support means5moves the coil at the same speed of the moving means of the one or more ends of the coils.

In the configuration shown inFIG. 1, the device50is provided with a station51, wherein the coils3supplied from two coiling apparatus1, are prepared by stripping the ends4,5, and mounting electrical contact on them.

Subsequently, the coils are transported in correspondence of an injection moulding station52, preferably a rotary moulding stations, comprising a plurality of moulds (not shown) arranged on a rotatable platform. Also one or more injection unit (injector) are also movable on the rotatable platform.

After the injection moulding step, the coils are transported in subsequent station53wherein means for carrying out the electric connection test the coils can be arranged.

A similar cable processing device50, and in particular a rotary injection moulding station, is disclosed into a patent application in the name of the Applicant (WO2011/077467), to which the coiling apparatus according the present application can be added to provide the cable to be processed. However, the use of the coiling apparatus is not limited to the above disclosed cable processing device50.