Wire take-up apparatus with tape applicator for applying tape to terminal end portion of wire

A wire take-up apparatus for applying wire to a wire spool includes a tape applicator assembly for automatically applying a length of adhesive tape to the outer terminal end portion of the wire applied to a spool in order to prevent the wire from unraveling from the spool. The tape applicator assembly includes a vacuum roller assembly including a vacuum roller element which is operative for releasably retaining a portion of a length of tape on the outer surface thereof so that the adhesive surface of the tape faces outwardly. The vacuum roller assembly is movable to a position wherein the tape on the vacuum roller element thereof contacts the wire on a wire spool to apply the tape to the wire.

BACKGROUND AND SUMMARY OF THE INVENTION 
The instant invention relates to apparatus for applying wire to spools and 
more particularly to a wire take-up apparatus which includes a tape 
applicator mechanism for applying a length of adhesive tape to the exposed 
free terminal end portion of the wire applied to a spool in order to 
prevent unraveling thereof. 
Wire take-up apparatus have been successfully utilized for applying wire to 
spools for many years. One of the most common and effective types of wire 
take-up apparatus comprises dual take-up reels which are alternatively 
operative for receiving wire from a continuous wire production facility, 
such as a cable extrusion line. An apparatus of this type generally 
comprises cross-over means for cutting the wire after a predetermined 
amount thereof has been applied to a first spool, and for then feeding the 
wire onto a second spool without interrupting the flow of wire. The 
heretofore available dual reel take-up apparatus have generally been 
constructed as either coaxial dual reel apparatus, or parallel axis dual 
reel apparatus. In either case, they have been found to be effective for 
taking up wire at relatively high speeds, such as speeds in excess of 2000 
feet per minute. Wire take-up apparatus of these types are illustrated in 
a 1984 article from Wire Journal International entitled "The Economic 
Impact of Dual Reel Take-Up Performance" by Stuart Walton and David 
Hoddinott, one of the co-inventors of the subject invention. 
One of the main difficulties with the heretofore available wire take-up 
apparatus is that once a predetermined length of wire has been wound onto 
a spool and the wire has been cut so that the spool can be removed from 
the apparatus, the free end portion of the wire on the full spool is loose 
and free to unravel therefrom. As a result, heretofore it has generally 
been necessary to manually remove a full wire spool from a wire take-up 
apparatus, to manually rewind the free terminal end portion of the wire 
thereon, and to then manually apply retaining means, such as a length of 
adhesive tape to the free terminal end portion of the wire. 
The instant invention represents a significant advancement in the art 
relating to wire take-up apparatus by providing means for automatically 
applying a length of adhesive tape to the terminal end portion of the wire 
on a spool as the wire is cut after a predetermined length thereof has 
been applied to the spool. More specifically, the wire take-up apparatus 
of the instant invention includes a vacuum roller having a resiliently 
cushioned outer surface, means for applying a vacuum to the outer surface 
of the vacuum roller, and means for supplying a length of adhesive tape to 
the vacuum roller so that the adhesive surface of the tape faces outwardly 
and so that the tape is retained on the vacuum roller by the vacuum means. 
The means for supplying a length of adhesive tape preferably includes a 
tape supply roll, and a tape accumulator between the tape supply roll and 
the vacuum roller for releasably accumulating a length of tape between the 
tape supply roll and the vacuum roller so that the tape in the accumulator 
can be rapidly dispensed to the vacuum roller from the accumulator. The 
apparatus further includes means for moving the vacuum roller with the 
tape thereon into engagement with the wire on the outer circumferential 
surface of a rotating spool of wire so that the tape is adhered to the 
wire and drawn from the vacuum roller and the accumulator as the wire 
spool is rotated. The apparatus further includes a tape knife assembly for 
cutting the tape after a length thereof has been applied to the wire on a 
wire spool. The means for moving the vacuum roller is preferably operative 
for moving the vacuum roller toward a spool of wire until the adhesive 
surface of the tape contacts the wire on the spool and for then 
immediately retracting the vacuum roller to a position of spaced 
disengagement from the spool. The tape knife assembly preferably includes 
a pivot arm having a free terminal end, a pivot head which is pivotally 
mounted on the pivot arm adjacent the free terminal end thereof, and a 
knife blade on the pivot head. The tape knife assembly preferably further 
includes means for pivoting the pivot arm to a position wherein the pivot 
head engages the adhesive surface of the tape between the vacuum roller 
and the adjacent spool of wire after a length of tape has been applied to 
the wire so that the tape causes the pivot head to be pivoted to a 
position wherein the knife blade contacts the tape to cut the latter. The 
apparatus preferably further includes a brake mechanism for braking the 
rotation of the vacuum roller immediately upon cutting the tape, and an 
air jet for urging the portion of the tape remaining after a cutting 
operation toward the vacuum roller so that the free end portion of the 
tape is retained on the vacuum roller. The brake means is preferably 
automatically released at a predetermined time interval after cutting the 
tape, and the apparatus preferably further includes a retaining finger 
which is automatically pivoted toward the vacuum roller so that it engages 
the adhesive surface of the tape to capture the tape between the retaining 
finger and the vacuum roller after a cutting operation in order to prevent 
movement of the tape in a reverse direction. 
It has been found that the tape applicator of the apparatus of the instant 
invention can be effectively utilized for applying an adhesive tape to a 
wire spool in a high-speed operation, and that as a result the tape 
applicator can be effectively utilized in a dual reel continuous wire 
take-up apparatus. Specifically, it has been found that the tape 
applicator of the instant invention can be effectively utilized for 
applying tape to the outer layers of wire on the wire spools of a wire 
take-up apparatus which is capable of operating with wire take-up speeds 
of 2000 feet per minute, or more. 
Accordingly, it is a primary object of the instant invention to provide an 
apparatus for automatically applying a length of tape to the wire on the 
outer surface of a wire spool. 
Another object of the instant invention is to provide a means for 
effectively automatically packaging a spool of wire without allowing the 
free outer end portion of the wire to unravel therefrom. 
An even still further object of the instant invention is to provide a high 
speed tape applicator apparatus which is operative for applying a length 
of tape to a wire on the outer surface of a wire spool in a continuous 
wire take-up apparatus. 
Other objects, features and advantages of the invention shall become 
apparent as the description thereof proceeds when considered in connection 
with the accompanying illustrative drawings.

DESCRIPTION OF THE INVENTION 
Referring now to the drawings, the apparatus of the instant invention is 
illustrated in FIGS. 1 through 9 and generally indicated at 10 in FIG. 1. 
The apparatus 10 comprises a wire take-up apparatus generally indicated at 
12, and a pair of tape applicator assemblies generally indicated at 14, and 
14a. The wire take-up apparatus 12 is configured as a conventional 
continuous dual reel take-up apparatus including first and second wire 
spools 18 and 18a, respectively, which are driven by first and second 
drive motor assemblies 19 and 19a, respectively, a wire traverse assembly 
generally indicated at 20, and a wire knife assembly generally indicated 
at 22. During operation of the apparatus 10, the wire take-up apparatus 12 
is operative for alternatively winding a continuous wire 24 onto the first 
wire spool 18, or the second wire spool 18a, and it is further operative 
for cutting the wire 24 and feeding it onto the other spool 18 or 18a so 
that the original spool 18 or 18a can be changed without interrupting the 
continuous advancement of the wire 24. The tape applicator assemblies 14 
and 14a are operative for applying lengths of tape 26 to the wire 24 on 
the spools 18 and 18a, respectively, after they have been filled with wire 
24 in order to retain the respective exposed terminal end portions of the 
wire 24 thereon. 
The wire take-up apparatus 12 is of conventional construction, the various 
components thereof being mounted and/or supported on the frame 16. The 
wire spools 18 and 18a are rotatably mounted so that they are driven by 
the drive motor assemblies 19 and 19a, respectively, and the wire traverse 
assembly 20 is mounted on the frame 16 above the spools 18 and 18a so that 
it is movable between the two positions thereof illustrated in FIG. 1. The 
traverse assembly 20 includes a pair of guide rollers 30 which are 
rotatably mounted on a frame 32 and it is operative for guiding the wire 
24 so that it is evenly wound onto the spools 18 and 18a. The wire knife 
assembly 22 includes a support 31, a pair of deflector bars 32, and a 
knife 34, and it is actuatable for cutting the wire 24 in a conventional 
manner. 
The wire take-up apparatus 12 preferably includes a conventional control 
assembly 35 which is operative for controlling the operation of the motors 
19 and 19a, the traverse assembly 20, and the wire knife assembly 22 in a 
conventional manner. Specifically, the control assembly 35 is preferably 
operative for determining when a predetermined amount of wire has been 
wound onto a particular spool 18 or 18a and for then repositioning the 
traverse assembly 20 to the opposite position thereof. The control 
assembly 35 is preferably further operative for then cutting the wire 24 
with the knife assembly 22, and guiding the wire 24 with the knife 
assembly 22 so that the wire is fed onto the empty spool 18 or 18a. More 
specifically, referring to the operation for the apparatus 12 as 
illustrated in FIG. 1, while the wire 24 is initially applied to the first 
wire spool 18, the traverse assembly 20 is normally located in the 
left-hand position thereof illustrated in phantom in FIG. 1. However, when 
a predetermined length of the wire 24 has been wound onto the spool 18 the 
drive motor assembly 19a is actuated and the traverse assembly 20 is moved 
to the right-hand position thereof illustrated in solid lines in FIG. 1. 
The knife assembly 22 is then operated by the controller 35 for cutting 
the wire 24 and for guiding the wire 24 so that it is wound onto the 
second spool 18a. At a predetermined relatively short time interval after 
the wire 24 has been cut, the motor 19 is deactuated so that the first 
full spool 18 can be removed from the apparatus 12 and replaced with 
another empty spool. 
The tape applicator assemblies 14 and 14a are identical with the exception 
that the applicator assembly 14a is a mirror image of the applicator 
assembly 14. Each of the tape applicator assemblies 14 and 14a comprises a 
tape supply roll assembly generally indicated at 36, an accumulator 
assembly generally indicated at 38, a vacuum roller assembly generally 
indicated at 40, a tape knife assembly generally indicated at 42, an air 
jet 44, and a pair of wire tail guides 46 and 48; and a pneumatic 
controller 49 is provided for controlling both of the tape applicators 14 
and 14a. During operation of each of the tape applicator assemblies 14 and 
14a, a length of tape 26 is drawn from the respective tape supply roll 
assembly 36 thereof and retained in the tape accumulator assembly 38 
thereof while the wire 24 is being wound onto the respective spool 18 or 
18a thereof. Once a predetermined quantity of wire 24 has been wound onto 
the respective spool 18 or 18a thereof, the wire 24 is cut with the wire 
knife assembly 22, and the vacuum roller assembly 40 thereof is moved into 
engagement with the wire 24 on the spool 18 or 18a to apply a length of the 
tape 26 to the free end portion of the wire 24 thereon. 
Each of the tape supply roll assemblies 36 comprises a supply roll 50 of 
tape, such as 3M Scotch Brand Pressure Sensitive Film Box Sealing Tape, 
which preferably has a width of approximately one and one-half inches. 
Each of the tape supply roll assemblies 36 further comprises a pneumatic 
brake assembly 51 which is actuatable for retaining the supply roll 50 in 
a stationary position, and a tension arm 52 having a tension roller 54 
mounted thereon which is biased to a position of engagement with the 
supply roll 50 thereof by means of a spring 56. Each of the tape supply 
roll assemblies 36 further comprises a plurality of guide rollers 57 which 
are operative for guiding the tape 26 from the respective tape supply roll 
50 thereof to the accumulator assembly 38 thereof. 
Each of the accumulator assemblies 38 comprises a track assembly 58, an 
upper end member 59, and a carriage member 60. Each of the accumulator 
assemblies 38 further includes a plurality of rollers 61 on the end member 
59 thereof and the carriage member 60 thereof. Each of the carriage members 
60 is received on the respective track assembly 58 thereof so that it is 
pneumatically repositionable thereon for movement toward an expanded, or 
loaded, position and so that it is also movable toward a contracted, or 
unloaded, position. In this regard, as illustrated in FIG. 1 the 
accumulator assembly 38 of the tape applicator 14a is disposed in the 
expanded or loaded position thereof, whereas the accumulator assembly 38 
of the tape applicator assembly 14 is disposed in the contracted, or 
unloaded, position. Each of the accumulator assemblies 38 is constructed 
so that it is normally operative for moving to the expanded position 
thereof under a pneumatic pressure of approximately 20 psi, and for 
resisting movement to the contracted position thereof under a pneumatic 
pressure of approximately 5 psi when a force is applied to the respective 
tape 26 thereof sufficient to longitudinally pull the latter from the 
accumulator assembly 38. Each of the accumulator assemblies 38 is 
operative for rapidly supplying a length of tape 26 to the respective 
vacuum roller assembly 40 thereof so that the tape 26 can be applied to 
the outer layers of the wire 24 on the respective wire spool 18 or 18a 
thereof while the latter is rotated at a high rate of rotation. Further, 
once a length of the tape 26 has been applied to the wire 24 on one of the 
spools 18 or 18a, the respective accumulator assembly 38 thereof is 
effectively pneumatically movable to the expanded position thereof as a 
new length of tape 26 is drawn from the supply roll 50. This operation of 
each of the accumulator assemblies 38 is coordinated with the respective 
tape supply roller assembly 36 thereof so that the brake assembly 51 of 
the respective supply roller assembly 36 is normally maintained in a 
braking position except while the accumulator assembly 38 thereof is being 
moved to the expanded position thereof. 
Each of the vacuum roller assemblies 40 comprises a carriage member or 
slide 62, a vacuum roller element 64, a brake assembly 66, a retaining 
finger assembly 68, a pneumatic piston assembly 70, and a roller and guide 
assembly 72. Each of the carriage members 62 has an elongated slot or track 
74 formed therein, and each includes a retaining member (not shown) which 
is receivable through the respective track 74 thereof for slidably 
retaining the carriage member 62 thereof on the frame 16. Each of the 
pneumatic piston assemblies 70 is operative for laterally repositioning 
the respective carriage member 62 thereof on the frame 16 in order to 
reposition the respective vacuum roller assembly 40 thereof relative to 
the respective spool 18 or 18a thereof. Each of the vacuum roller elements 
64 is rotatably mounted on the carriage member 62 thereof as will 
hereinafter be more fully set forth, and each of the brake assemblies 66 
is operative for applying a braking force to the respective vacuum roller 
element 64 thereof in order to arrest the rotation thereof, as will also 
hereinafter be more fully set forth. Each of the retaining finger 
assemblies 68 is pivotally mounted on the respective carriage member 62 
thereof, and each is biased toward the respective roller element 64 
thereof so that each retaining finger assembly 68 engages the respective 
tape 26 thereof to retain the tape 26 thereof in engagement with the 
respective vacuum roller element 64 thereof and to prevent movement of the 
tape 26 thereof in a reverse direction. Each of the guide roller assemblies 
72 is operative for guiding the respective tape 26 thereof from the 
respective accumulator assembly 38 thereof to the respective vacuum roller 
element 64 thereof. 
Referring to FIGS. 4 through 6, each of the vacuum roller elements 64 is 
mounted on the respective carriage member 62 thereof with a shaft and 
bearing assembly generally indicated at 75 comprising a vacuum shaft 
generally indicated at 76, a bearing 80, a one-way clutch bearing 82, a 
retainer piece 84, and an end cap 86. Each of the shafts 76 includes a 
tapered threaded end portion 88 which is connected to a vacuum source by 
means of a vacuum fitting 89, an enlarged section 90, a slightly reduced 
intermediate section 91, a flange 92 between the enlarged section 90 and 
the intermediate section 91, a further reduced end section 93 and a 
retaining ring groove 94. An axial bore 96 extends axially inwardly into 
each of the shafts 76 from the threaded end portion 88 thereof to a point 
which is closely spaced inwardly from the opposite end of the shaft 76, 
and a bore 98 extends outwardly from the axial bore 96 to an open channel 
100 which extends over an arc of approximately 120.degree. on the surface 
of the enlarged section 90 thereof. Each of the vacuum roller elements 64 
includes a wheel portion 102 which is preferably made from a relatively 
light weight metal, such as aluminum, and includes a hub section 104. Each 
of the vacuum roller elements 64 further includes an outer layer 106 which 
is preferably made from a resilient elastomeric material in a thickness of 
at least approximately 1/2 inch. A plurality of bores 108 having diameters 
of approximately 1/16th inch extend outwardly from the inner diameter of 
the hub portion 104 of each of the vacuum roller elements through the 
wheel portion 102 thereof and the outer layer 106 thereof, the bores 108 
preferably being angularly spaced at intervals of approximately 20.degree. 
in the vacuum roller elements 64. Each of the vacuum roller elements 64 is 
adapted to be rotatably mounted on the enlarged portion 90 of the 
respective shaft 76 thereof with the respective bearing 80 and clutch 
bearing 82 thereof received on the enlarged portion 90 so that a portion 
of the bores 108 in the vacuum roller element 64 communicate with the 
channel 100 in the shaft 76 thereof. Accordingly, at any given time a 
portion of the bores 108 extending over an arc of approximately 
120.degree. are aligned with the respective channel 100 thereof to apply 
vacuum to a vacuum segment of the outer surface of the respective vacuum 
roller element 64 thereof extending over an arc of approximately 
120.degree.. Each of the vacuum shafts 76 is non-rotatably mounted on the 
respective carriage 62 thereof so that the vacuum segment on the outer 
surface of the vacuum roller element 64 thereof extends upwardly from the 
lower side of the vacuum roller element 64 to a point which faces the 
adjacent spool 18 or 18a. Each of the bearings 80 is assembled in the hub 
section 104 of the vacuum roller element 64 thereof for rotatably mounting 
the latter on the shaft 76, and each of the one-way clutch bearings 82 is 
received on the shaft 76 thereof and assembled in the hub section 104 
thereof so that the clutch bearing 82 thereof is operative for preventing 
rotation of the respective vacuum roller element 64 thereof in a reverse 
direction. Each of the retaining elements 84 is received on the terminal 
end of the respective shaft 76 thereof for retaining the respective clutch 
82, vacuum roller 64 and bearing 80 thereon. Further, each of the end caps 
86 is assembled on the respective hub section 104 thereof for enclosing 
the clutch 82 and the retaining element 84 thereof, and for further 
retaining the respective clutch 82, vacuum roller element 64, and bearing 
80 thereof on the shaft 76 thereof in a manner which seals the vacuum at 
the end of the hub section 104. Each of the shafts 76 is received in a 
bore (not shown) in the carriage member 62 thereof, and a set screw (not 
shown) is provided for non-rotatably retaining each of the shafts 76 in 
assembled relation with the respective carriage member 62 thereof. 
One of the brake assemblies 66 is illustrated in FIGS. 2 and 3 and it 
includes a pneumatic piston assembly 110 having a piston rod 112, a 
connecting rod 114, and a brake element 116. Each of the pneumatic piston 
assemblies 110 is mounted on the carriage 62 thereof and each is operative 
for vertically repositioning the respective piston rod 112 thereof. Each of 
the brake elements 116 includes a mounting shaft 118 and each is pivotally 
mounted on the carriage 62 thereof with a pivot block 120, so that the 
shaft 118 thereof extends through the pivot block 120 thereof to the 
connecting rod 114 thereof. Accordingly, by vertically repositioning one 
of the piston rods 112, the pivot shaft 118 thereof is rotated in the 
pivot block 120 thereof to pivot the brake element 116 thereof. Each of 
the brake elements 116 is formed as an arcuate paddle-like braking element 
and each has an arcuate inner surface 122 which substantially conforms to 
the outer configuration of the outer layer 106 of the respective vacuum 
roller element 64 thereof. Accordingly, by actuating one of the pneumatic 
piston assemblies 110 to pivot the pivot shaft 118 thereof, the inner 
surface 122 of the brake element 116 thereof can be moved from a position 
of spaced disengagement from the outer surface of the adjacent vacuum 
roller element 64, to a position of pressurized braking engagement 
therewith. Each of the brake elements 116 preferably further includes a 
relatively stiff brush-like fabric, such as a velcro (Velcro U.S.A. TM), 
hook-type fabric on the outwardly facing surface thereof to prevent the 
tape 26 from adhering thereto in the event that the adhesive surface of 
the tape 26 inadvertently contacts the brake element 116. 
Each of the retaining finger assemblies 68 comprises a retaining finger 
element 124 which is preferably made from fiber-reinforced plastic, a 
pivot shaft 126, and a pair of retaining wires 128. Each of the retaining 
finger elements 124 preferably has a brush-like stiff pile fabric, such as 
Velcro (Velcro U.S.A. TM) on the surface thereof which faces generally 
angularly upwardly toward the respective vacuum roller element 64 thereof 
to prevent the tape 26 from adhering thereto. Further, each of the 
retaining finger elements 124 includes a terminal end 130 and each is 
rotatably mounted on the pivot shaft 126 thereof. Each of the shafts 126 
is non-rotatably mounted on the carriage 62 thereof for pivotally mounting 
the retaining finger element 124 thereof and each of the retaining finger 
elements 124 is biased toward a position wherein the terminal end 130 
thereof urges the adjacent tape 26 against the outer surface of the vacuum 
roller element 64 thereof with a spring 132. Further, the retaining fingers 
124 are angularly oriented relative to the respective vacuum roller 
elements 64 thereof so that they function as cam cleats for preventing 
movement of the tapes 26 in reverse directions back toward the respective 
accumulators 38 thereof as the respective accumulators 38 thereof are 
moved to expanded positions after the respective tapes 26 thereof have 
been cut. 
Each of the shafts 126 preferably also has a tubular passage therethrough, 
and each of the retaining finger elements 124 preferably has a plurality 
of tubular bores therein which communicate with the passage in the shaft 
126 thereof and open outwardly through the respective terminal end 130 
thereof. Each of the shafts 126 is connected to an air supply tube 132 for 
supplying air thereto so that the air passes outwardly through the bores at 
the terminal end 130 of the retaining finger element 124 thereof. The air 
which normally flows outwardly from the terminal end 130 of each of the 
retaining finger elements 124 operates to further urge the tape 26 thereof 
toward the vacuum roller element 64 thereof just after the tape has been 
cut. A plurality of the retaining wires 128 extends outwardly from each of 
the retaining finger elements 124 to prevent the respective tape 26 thereof 
from falling away from the vacuum roller element 64 thereof immediately 
after the tape 26 has been cut. 
Each of the roller and guide assemblies 72 includes a pair of rollers 134 
and 136, a pair of lower and upper guide plates 138 and 140 respectively, 
and a retaining plate 142. The rollers 134 and 136 preferably comprise 
freely rotatable rollers which include non-stick outer surface layers made 
from a suitable non-stick material such as Teflon (Dupont TM). The guide 
plates 138 and 140 are positioned in closely spaced substantially parallel 
relation so that they are operative for guiding the tapes 26 between the 
respective guide rollers 134 and 136 thereof, and each of the lower guide 
plates 138 preferably has a brush-like stiff pile fabric thereon, such as 
a velcro (Velcro U.S.A. TM) hook-type fabric, in order to prevent the 
adhesive surface of the tape 26 from adhering thereto. The retaining 
plates 142 are provided on the respective rollers 136 thereof in order to 
properly align the respective tapes 26 therewith before the tapes 26 are 
passed between the respective guide plates 138 and 140 thereof. 
One of the knife assemblies 42 is illustrated in FIGS. 2 and 3. As will be 
seen, each of the knife assemblies 42 includes a knife arm 144 which is 
pivotally mounted on the shaft 76 thereof, a pivot head 146, a return 
spring 147 and a plurality of knife blade elements 148 on the respective 
pivot head 146 thereof adjacent the outer terminal end thereof. Each of 
the pivot heads 146 is preferably made from a non-stick material, such as 
Teflon (Dupont TM), and each has an arcuate surface thereon which is 
engageable with the adhesive surface of the tape 26 for pivoting the 
respective pivot head 146 thereof to a position wherein the knife elements 
148 thereon engage the tape 26 thereof, as will hereinafter be more fully 
set forth. Each of the pivot heads 146 is biased toward the position 
illustrated in FIGS. 7 and 8 with the respective return spring 147 
thereof. Each of the knife assemblies 42 preferably includes at least six 
knife elements 148 which are positioned in a line extending across the 
arcuate surface of the respective pivot head 146 thereof. The knife 
elements 148 preferably have points which are formed in triangular 
pyramid-like configurations to provide relatively sharp points at the 
terminal ends thereof which are capable of readily penetrating the 
respective tape 26 thereof. Each of the knife assemblies 42 further 
includes a sprocket 150 which is rotatably received on the shaft 76 
thereof so that it abuts the shoulder formed by the end of the 
intermediate section 91 thereof. Each of the sprockets 150 is attached to 
the pivot arm 144 thereof for pivoting the latter, and a retaining ring 
152 is received in the retaining groove 94 on the respective shaft 76 
thereof for retaining the respective sprocket 150 thereon. Further 
included in each of the knife assemblies 42 is a drive chain 154 which 
extends from the sprocket 150 thereof to a second sprocket 156 thereof. 
Each of the second sprockets 156 is rotatably mounted on the carriage 62 
thereof, and a pneumatic rotary drive 158 is provided on the opposite side 
of the carriage 62 thereof from the respective sprocket 156 thereof, for 
selectively rotating the latter in clockwise and counterclockwise 
directions. Accordingly, by actuating the pneumatic rotary drive 158 of 
one of the knife assemblies 42 the sprocket 156 thereof is rotated to 
rotate the sprocket 150 thereof and pivot the knife arm 144 thereof. 
The operation of one of the knife assemblies 42 is illustrated most clearly 
in FIGS. 8 and 9. As will be seen, during normal operation, and even during 
the initial stages of applying a section of the tape 26 to the wire 24 on 
one of the spools 18 or 18a, the respective knife arm 144 thereof is 
maintained in a generally downwardly extending position wherein the pivot 
head 146 thereof and the knife elements 148 thereof are in spaced relation 
to the adjacent tape 26. However, once a quantity of tape 26 has been 
applied to the wire 24 on one of the spools 18 or 18a, the respective 
carriage 62 thereof is moved back away from the spool 18 or 18a, and the 
respective knife arm 144 thereof is immediately pivoted upwardly by the 
rotary drive 158 thereof to a position wherein the arcuate surface of the 
respective pivot head 146 contacts the adhesive surface of the adjacent 
tape 26. This causes the former to be rapidly pivoted so that the knife 
elements 148 thereon contact the adhesive surface of the adjacent tape 26. 
As a result, the knife elements 148 sever the portion of the tape 26 which 
has been applied to the wire 24 on the spool 18 or 18a from the remaining 
portion of the tape 26 on the adjacent vacuum roller 64. After the tape 26 
has been cut in this manner the knife arm 144 thereof is returned to its 
normal downwardly extending position by the rotary drive 158 thereof, and 
the respective pivot head 146 is returned to its original position by the 
return spring 147 thereof. 
Each of the air jets 44 is mounted on the frame 16 and connected to a 
source of pressurized air. Each of the air jets 44 is positioned and 
directed so as to provide an air stream which urges the free end portion 
of the adjacent tape 26 upwardly after the latter has been cut with the 
respective knife assembly 42 thereof so that the free end portion of the 
tape 26 is moved upwardly toward the outer surface of the respective 
vacuum roller element 64 thereof. 
The wire tail guides 46 and 48 are operative for guiding the wire 26 as it 
is wound onto the spools 18 and 18a. Each of the wire tail guides 46 is 
mounted in a stationary position beneath the respective wire spool 18 or 
18a thereof and each is constructed and positioned for guiding the tail of 
the cut wire 24 onto the respective adjacent wire spool 18 or 18a thereof 
so that it is aligned with the respective adjacent vacuum roller 64 
thereof. Each of the wire tail guides 48 is mounted on the frame 16 
between the respective wire tail guide 46 thereof and the wire knife 
assembly 22. Further, each of the wire tail guides 48 is adapted so that 
it is pneumatically vertically repositionable between the raised or 
operative position of the wire tail guide 48 of the applicator 14 
illustrated in the left hand portion of FIG. 1 and the lowered or 
inoperative position of the wire tail guide 48 of the applicator 14a 
illustrated in the right hand portion of FIG. 1. Each of the wire tail 
guides 48 is pneumatically moved to the operative position just before the 
wire 24 is cut with the wire knife assembly 22 so that the wire tail guide 
48 guides the wire 24 onto the respective spool 18 or 18a thereof during a 
wire cutting operation. Further, each of the wire tail guides 48 is 
operative for guiding the free end portion of the wire 24 onto the 
respective spool 18 or 18a thereof immediately following a wire cutting 
operation. 
The controller 49 comprises a conventional pneumatic controller, and as 
herein embodied the controller 49 is adapted for performing a dual 
function of controlling both the applicator 14 and the applicator 14a. It 
will be understood, however, that other embodiments which include separate 
controllers for the applicators 14 and 14a and other embodiments wherein 
the controller 49 is formed as part of the controller 35 are contemplated. 
In any event, the controller 49 as herein embodied comprises a conventional 
controller which is programmable by conventional programming techniques for 
controlling the operation of the tape applicators 14 and 14a as herein 
described. 
Referring again to FIG. 1, during operation of the apparatus 10 for 
applying the wire 24 to the spool 18, the drive motor assembly 19 is 
operated to rotate the spool 18, while the traverse assembly 20 is located 
in a position above the tape applicator assembly 14. The traverse assembly 
20 is controlled by the controller 35 for evenly applying the wire 24 to 
the spool 18 by traversing back and forth relative to the circumferential 
surface defined by the wire 24 on the spool 18. Once a predetermined 
quantity of the wire 24 has been wound onto the spool 18, the traverse 
assembly 20 is automatically moved to a position above the applicator 
assembly 14a so that the wire 24 passes in front of the wire knife 
assembly 22 and the drive motor assembly 19a is actuated. The wire guide 
48 is then moved upwardly in front of the spool 18 when the wire 24 is at 
a location on the surface of the spool 18 which is aligned with the vacuum 
roller 64 so that the wire guide 48 maintains the wire 24 in aligned 
relation with the adjacent vacuum roller 64. The wire knife assembly 22 is 
then operated for cutting the wire 24 so that the wire 24 is simultaneously 
fed onto the spool 18a and at approximately the same time the controller 49 
operates to control the operation of the applicator 14 by actuating piston 
assembly 70 for moving the carriage 62 inwardly so that the tape 26 on the 
vacuum roller 64 engages the wire 24 on the spool 18. Further, when the 
piston assembly 70 is actuated for moving the carriage 62 inwardly, the 
pneumatic pressure to the accumulator assembly 38 is reduced by the 
controller 49 to enable the tape to be drawn at reduced tension from the 
accumulator assembly 38 as it is applied to the wire 24 on the spool 18. 
As soon as the tape on the vacuum roller 64 contacts the wire on the spool 
18, the carriage 62 is immediately retracted by the piston assembly 70, and 
the controller 49 operates to apply braking pressure to the vacuum roller 
64 with the brake assembly 66 to arrest further rotation of the vacuum 
roller 64. Further, the controller 49 operates to pivot the knife arm 144 
upwardly with the rotary drive 158 so that the arcuate surface of the 
pivot member 146 contacts the adhesive surface of the tape 26 in the area 
where the tape 26 extends between the vacuum roller 64 and the spool 18. 
As the pivot member 42 contacts the tape 26 it is pivoted upwardly by the 
tape so that the knife elements 148 penetrate the tape 26 to cut the 
latter between the vacuum roller 64 and the spool 18. As a result, a 
length of tape 26 is applied to the free end portion of the wire 24 on the 
spool 18 as the spool 18 is rotated to retain the free end portion of the 
wire 24 thereon against unwinding. Once the tape 26 has been cut in this 
manner the remaining end portion of the tape is retained by the wires 128, 
and then moved upwardly by the air from the air jet 44 and the air passing 
outwardly from the apertures at the end of the retaining finger 124. Once 
the remaining end portion of the tape 26 is brought into contact with the 
vacuum roller 64, the vacuum which is constantly applied to the vacuum 
roller 64 through the apertures 108 operates to maintain the tape 26 in 
engagement with the vacuum roller 64. At this point the controller 49 
operates to release the brake assembly 66 so that braking pressure is no 
longer applied to the vacuum roller element 64. Further, the retaining 
finger 124 which is resiliently biased toward the vacuum roller 64 
operates to prevent the tape 26 from traveling in a reverse direction back 
toward the accumulator 38. Once the tape 26 has been cut in this manner the 
controller 49 operates the rotary drive 158 to return the knife arm 144 to 
the downwardly extending position illustrated in FIGS. 1, 2, 7, and 8, and 
the return spring 147 returns the pivot member 146 to the normal position 
thereof illustrated in FIGS. 1, 2, 7, and 8. Once the carriage 62 has been 
returned to its initial position, the brake 51 on the tape roll 50 is 
released by the controller 49 and the pneumatic pressure to the 
accumulator assembly 38 is increased by the controller 49 so that the 
accumulator assembly 38 is moved to the original loaded, or extended, 
position thereof wherein a predetermined length of tape 26 is contained 
thereon. Once the accumulator assembly 38 has been filled with tape the 
brake 51 is reapplied to the tape supply roll 50 by the controller 49, and 
the motor drive assembly 19 is deactuated by the controller 35 so that the 
spool 18 can be removed from the apparatus 10 and replaced with an empty 
spool. Thereafter, when a predetermined length of wire 24 has been applied 
to the spool 18a, a similar operation is carried out wherein the wire 24 is 
again cut and a section of tape 26 is applied to the wire 24 on the spool 
18a with the tape applicator 14a. 
It is seen therefore that the instant invention provides an effective wire 
take-up apparatus. The apparatus 10 includes the tape applicators 14 and 
14a which are operative for applying the tapes 26 to the respective spools 
18 and 18a thereof so that the wire 24 on the spools 18 and 18a does not 
become unwound, and so that the spools 18 and 18a can be loaded and 
unloaded in an automated operation. Accordingly, the apparatus 10 is 
operative for applying wire to spools at substantially increased rates of 
speed, and it can be utilized in a totally automated operation wherein 
spools 18 and 18a of wire 24 are filled and removed from the apparatus 10 
at a high rate of speed. Hence, it is seen that the instant invention 
represents a significant advancement in the art relating to wire take-up 
apparatus which has substantial commercial merit. 
While there is shown and described herein certain specific structure 
embodying the invention, it will be manifest to those skilled in the art 
that various modifications and rearrangements of the parts may be made 
without departing from the spirit and scope of the underlying inventive 
concept and that the same is not limited to the particular forms herein 
shown and described except insofar as indicated by the scope of the 
appended claims.