Patent Description:
The invention relates to a method and a machine to manufacture at least two different coils around a component of an article.

The invention finds advantageous application on the tobacco industry to manufacture an electronic component of a disposable cartridge of an electronic cigarette, to which explicit reference will be made in the description below without because of this losing in generality.

An electronic cigarette normally comprises a re-usable part, which is used several times and contains, among other things, an electric battery (which provides the power needed for the operation of the electronic cigarette) and an electronic processor, which controls the operation of the electronic cigarette. Furthermore, the electronic cigarette comprises a disposable cartridge (namely to be used one single time and to be then replaced), which is coupled to the re-usable part.

Recently, a disposable cartridge was developed, which is provided with a transponder equipped with a memory where the features of the disposable cartridge are stored, in particular the features of the (liquid or solid) active substance that has to heated in order to release the vapours to the inhaled; in this way, the re-usable part of the electronic cigarette can read the features of the disposable cartridge coupled thereto, accordingly adjusting the heating to the features of the disposable cartridge.

In most applications, the transponder comprises one single wound antenna (namely, one single coil serving as antenna); however, in some applications, the transponder can comprise a plurality of antennas (namely, a plurality of coils serving as antennas), which have different spatial orientations so as to make sure that the transponder is capable of effectively communicating in all possible positions.

<CIT> discloses a conveyor apparatus for workpieces which are to undergo processing operations along the path of the apparatus.

The object of the invention is to provide a method and a machine to manufacture at least two different coils around a component of an article, said method and said machine allowing users to operate at a high operating speed (measured as number of components produced per time unit), ensuring, at the same time, a high productive quality (generally measured as percentage of faulty pieces).

According to the invention there are provided a method and a machine to manufacture at least two different coils around a component of an article as claimed in the appended claims.

The appended claims describe preferred embodiments of the invention and form an integral part of the description.

In <FIG> and <FIG>, reference number <NUM> indicates, as a whole, a component of a disposable cartridge of an electronic cigarette.

The component <NUM> approximately has the shape of a parallelepiped having six walls (faces): an upper wall <NUM>, a lower wall <NUM>, which is parallel to and opposite the upper wall <NUM>, a front wall <NUM>, a rear wall <NUM>, which is parallel to an opposite the front wall <NUM>, and two side walls <NUM> and <NUM>, which are parallel to and opposite one another.

The component <NUM> comprises an integrated electronic circuit (not shown), which is arranged inside the component, is generally provided with an electric battery of its own (namely, has a power source of its own) and has six pairs of electrical contacts <NUM>, which are arranged in the area of the walls <NUM>-<NUM>: a pair of electrical contacts <NUM> is arranged in the area of the side wall <NUM>, two pairs of electrical contacts <NUM> are arranged in the area of the front wall <NUM>, a pair of electrical contacts <NUM> is arranged in the area of the side wall <NUM>, and two pairs of electrical contacts <NUM> are arranged in the area of the rear wall <NUM>. Furthermore, the component <NUM> comprises six coils <NUM>-<NUM>, which are wound: two coils <NUM> and <NUM> with a larger size (area), which surround the walls <NUM>-<NUM> and are arranged at the opposite ends of the component <NUM> (namely, the coil <NUM> is arranged close to the upper wall <NUM>, whereas the coil <NUM> is arranged close to the lower wall <NUM>), two coils <NUM> and <NUM> with an intermediate size (area), which surround the walls <NUM>-<NUM> and <NUM>-<NUM> and are arranged at the opposite ends of the component <NUM> (namely, the coil <NUM> is arranged close to the front wall <NUM>, whereas the coil <NUM> is arranged close to the rear wall <NUM>), and two coils <NUM> and <NUM> with a smaller size (area), which surround the walls <NUM>-<NUM> and are arranged at the opposite ends of the component <NUM> (namely, the coil <NUM> is arranged close to the side wall, <NUM> whereas the coil <NUM> is arranged close to the side wall <NUM>).

Each coil <NUM>-<NUM> is wound and consists of a plurality of turns of an externally insulated conductor wire <NUM>, which form a winding; in the embodiment shown in the accompanying figures there are approximately <NUM>-<NUM> turns. Each coil <NUM>-<NUM> (namely, the wound wire <NUM> making up each coil <NUM>-<NUM>) has two ends (obviously, an initial end and a final end depending on the winding direction), which are welded to a corresponding pair of electrical contacts <NUM>.

The electronic circuit of the component <NUM> uses the six coils <NUM>-<NUM> in an alternative or simultaneous manner in order communicate, through radio frequency, with other electronic devices arranged nearby. Alternatively or in addition, the electronic circuit of the component <NUM> could also use the six coils <NUM>-<NUM> to generate power (used for its own operation and/or to charge its own electric battery) exploiting an electromagnetic field generated by an electronic device arranged nearby; namely, the electronic circuit of the component <NUM> could also use the six coils <NUM>-<NUM> to carry out an inductive (namely contactless) power charging of its own electric battery. As a consequence, the six coils <NUM>-<NUM> of the component <NUM> constitute corresponding antennas, which can be used to exchange information by means of electromagnetic waves (in this case, the antennas are part of a telecommunication device) and/or can be used to exchange power by means of electromagnetic waves (in this case, the antennas are part of a charging device). Finally, the component <NUM> comprises six pairs of pins <NUM> and <NUM> (namely, two small columns), which protrude in a projecting manner (namely, perpendicularly) from the corresponding walls <NUM>-<NUM> and are arranged close to corresponding pairs of electrical contacts <NUM>; the two (initial and final) ends of the wound wire <NUM> making up each coil <NUM>-<NUM> are bent by (circa) <NUM>° around the corresponding pins <NUM> or <NUM> before being fitted into the electrical contacts <NUM> (namely, before reaching the corresponding electrical contacts <NUM> to which the two ends are welded).

It should be pointed out that the position and the shape of the electrical contacts <NUM> and of the pins <NUM> and <NUM> could be completely different, provided that each coil <NUM>-<NUM> is associated with two respective electrical contacts <NUM> and two respective pins <NUM> and <NUM> and that the pins <NUM> and <NUM> are arranged (relatively) close to the electrical contacts <NUM>.

In the embodiment shown in the accompanying figures, the component <NUM> comprises six coils <NUM>-<NUM>; according to other embodiments, which are not shown herein, the component <NUM> has a different number of coils <NUM>-<NUM>, which generally ranges from two to five (but, in some cases, there can even be more than six coils <NUM>-<NUM>).

In <FIG> and <FIG>, reference number <NUM> indicates, as a whole, a machine to manufacture the coils <NUM>-<NUM> in the component <NUM>.

The machine <NUM> comprises a support body (namely, a frame), which rests on the ground by means of legs and has, at the front, a vertical wall on which the operating members are mounted. Furthermore, the machine <NUM> comprises a main conveyor <NUM>, which moves the components <NUM> being processed along a winding path P, which develops between an input station S1 (where the main conveyor <NUM> receives the components <NUM> to be provided with the coils <NUM>-<NUM>) and an output station S2 (where the main conveyor <NUM> releases the complete components <NUM>, namely provided with the coils <NUM>-<NUM>).

The winding path P goes through a series of stations S3-S19 (better described below), where the operations for manufacturing the six coils <NUM>-<NUM> are carried out. In the embodiment shown in the accompanying figures, the main path P comprises one single horizontal and linear segment (namely, substantially developing along a straight line arranged horizontally) arranged between the input station S1 and the output station S2; according to a different embodiment, which is not shown herein, the winding path P comprises: an upper segment, which is horizontal and linear, a lower segment, which is horizontal and linear (and, hence, is parallel to the upper segment), and a semicircular joining segment, which connects the upper segment and the lower segment to one another. The main conveyor <NUM> comprises a plurality of carriages <NUM>, which are moved along the winding path P; as better shown in <FIG>, <FIG> and <FIG>, each carriage <NUM> comprises a support plate <NUM>, in which three different seats <NUM>, <NUM> and <NUM> are obtained, each designed to receive and house the same component <NUM> with different orientations. Namely, the seat <NUM> is designed to accommodate the component <NUM> when the side wall <NUM> or the side wall <NUM> of the component <NUM> rests on the support plate <NUM>, the seat <NUM> is designed to accommodate the component <NUM> when the front wall <NUM> or the rear wall <NUM> of the component <NUM> rests on the support plate <NUM>, and the seat <NUM> is designed to accommodate the component <NUM> when the upper wall <NUM> or the lower wall <NUM> of the component <NUM> rests on the support plate <NUM>. Hence, each support plate <NUM> is suited to support one single component <NUM>, which can be arranged with three different orientations and in six different positions (each orientation entails two different positions).

According to a preferred embodiment, which is better shown in <FIG>, each seat <NUM>, <NUM> or <NUM> comprises a clamp <NUM>, which is closed to firmly hold a component <NUM> resting on the support plate <NUM> and is opened to release a component <NUM> resting on the support plate <NUM>. Each clamp <NUM> comprises two opposite jaws <NUM>, which are arranged at the opposite ends of the seat <NUM>, <NUM> or <NUM>, are movable by means of a linear movement (which develops parallel to the winding path P) and, in use, move between a holding position, in which the two jaws <NUM> are closer to one another and clamp a component <NUM> resting on the support plate <NUM>, and a release position, in which the two jaws <NUM> are farther from one another and release a component <NUM> resting on the support plate <NUM>. The clamps <NUM> are all controlled together by a same actuator device <NUM> (namely, all three clamps <NUM> open and close at the same time), which can be mounted on the support plate <NUM> or can be on the outside of the support plate <NUM> and be arranged in a fixed position beside the main conveyor <NUM>. Preferably, each clamp <NUM> normally is closed, namely, in the absence of an intervention of the actuator device <NUM>, it naturally remains closed; this result is obtained thanks to the presence of a spring, which tends to push the jaws <NUM> of each clamp <NUM> towards the closed position and is compressed by the action of the actuator device <NUM> (namely, the actuator device <NUM> must overcome the elastic force generated by the spring in order to move the jaws <NUM> of each clamp <NUM> towards the open position). According to a different embodiment, each clamp <NUM> has an actuator device <NUM> of its won, which is separate from and independent of the actuator devices <NUM> of the other two clamps <NUM>; in this way, each actuator device <NUM> is optimized for the stroke of the jaws <NUM> of the corresponding clamp <NUM>.

It should be pointed out that the three clamps <NUM> of the three seats <NUM>, <NUM> and <NUM> of a same support plate <NUM> are the same from a functional point of view (namely, they are all designed to grab and hold the component <NUM> in three different positions), but they could be different from a structural point of view (namely, have different shapes) in order to adjust themselves to the conformation of the component <NUM>.

Obviously, the number of seats <NUM> obtained in the support plate <NUM> of each carriage <NUM> could be other than three depending on the number of coils <NUM>-<NUM> to be manufactured and on the conformation of the component <NUM>; hence, the support plate <NUM> of each carriage <NUM> could have one single seat <NUM>, <NUM> or <NUM> or two seats <NUM>, <NUM> or <NUM> or even more than three seats <NUM>, <NUM> or <NUM>.

The main conveyor <NUM> is designed to cyclically move each carriage <NUM> along the winding path P with an intermittent (step-like) movement, which entails cyclically alternating movement phases, in which the main conveyor <NUM> moves the carriages <NUM>, and stop phases, in which the main conveyor <NUM> holds the carriages <NUM> still. According to <FIG>, the main conveyor <NUM> comprises an annular guide <NUM> (namely, closed on itself with a ring shape), which is arranged in a fixed position along the winding path P; in particular, the annular guide <NUM> consists of one single fixed track (namely, without movement), which is arranged along the winding path P. Furthermore, the main conveyor <NUM> comprises a plurality of slides <NUM>, each supporting a corresponding carriage <NUM> and being coupled to the guide <NUM> so as to freely slide along the guide <NUM>. Finally, the main conveyor <NUM> comprises a linear electric motor <NUM>, which moves the slides <NUM> carrying the carriages <NUM> along the winding path P; furthermore, the linear electric motor <NUM> comprises an annular stator <NUM> (namely, a fixed primary element), which is arranged in a fixed position along the guide <NUM>, and a plurality of movable sliders <NUM> (namely, movable secondary elements), each electrically-magnetically coupled to the stator <NUM> so as to receive, from the stator <NUM>, a driving force and rigidly connected to a corresponding slide <NUM>.

According to a different embodiment, which is not shown herein, the main conveyor <NUM> is a conveyor belt and comprises (at least) a flexible belt, which supports the carriages <NUM> and is closed in a ring shape around at least two end pulleys (at least one of them being motor-driven). According to a further embodiment, which is not shown herein, the main conveyor <NUM> is a drum (arranged in a vertical horizontal manner), which is mounted so as to rotate around a central rotation axis; obviously, in this embodiment, the winding path P has a circular shape.

In the description below, the functions of the stations S <NUM>-S <NUM> of the machine <NUM> will be explained with reference to one single carriage <NUM> moving one single component <NUM>.

According to <FIG> and <FIG>, at the beginning of the manufacturing cycle of the coils <NUM>-<NUM>, the main conveyor <NUM> moves the carriage <NUM> (carrying three seats <NUM> to be used alternatively) along the winding path P so as to stop one single carriage <NUM> in the input station S1, in which one single component <NUM> is placed in the seat <NUM> of the carriage <NUM> by laying the side wall <NUM> on the support plate <NUM> (namely, with the side wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the input station S1 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> holding it on part of the walls <NUM> and <NUM> (namely, leaving the side walls <NUM> and <NUM> completely free); when the carriage <NUM> is standing still in the input station S1, the motor-driven arm <NUM> inserts a component <NUM> in the seat <NUM> of the carriage <NUM> by laying the side wall <NUM> on the support plate <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the input station S1 to the winding station S3, in which the carriage <NUM> stops and in which a winding unit <NUM> (which is shown more in detail in <FIG>) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station S3 to the welding station S4 (arranged downstream of the winding station S3), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S3, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (shown more in detail in <FIG>).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S4 to the handling station S5 (arranged downstream of the welding station S4), in which the carriage <NUM> stops and in which the component <NUM> is turned upside-down (namely, rotated around itself by <NUM>°) in order to be placed in the seat <NUM> of the carriage <NUM> by laying the side wall <NUM> on the support plate <NUM> (namely, with the side wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the handling station S5 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> holding it on part of the walls <NUM> and <NUM> (namely, leaving the side walls <NUM> and <NUM> completely free); when the carriage <NUM> is standing still in the handling station S5, the motor-driven arm <NUM> grabs the component <NUM> standing in the seat <NUM> of the carriage <NUM> and rotates it around itself by <NUM>° so as to lay the side wall <NUM> on the support plate <NUM> (the side wall <NUM>, which is opposite the side wall <NUM>, was previously resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S5 there also is a removal unit <NUM>, which, while the motor-driven arm <NUM> changes the position of the component <NUM> on the support plate <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the handling station S5 to the winding station S6, in which the carriage <NUM> stops and in which a winding unit <NUM> (completely identical to the winding unit <NUM> present in the winding station S3) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station S6 to the welding station S7 (arranged downstream of the winding station S6), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S6, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> present in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S7 to the handling station S8 (arranged downstream of the welding station S7), in which the carriage <NUM> stops and in which the component <NUM> is rotated by <NUM>° in order to be placed in the seat <NUM> of the carriage <NUM> by laying the front wall <NUM> on the support plate <NUM> (namely, with the rear wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the handling station S8 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> leaving the front wall <NUM> completely free; when the carriage <NUM> is standing still in the handling station S8, the motor-driven arm <NUM> grabs the component <NUM> standing in the seat <NUM> of the carriage <NUM> and rotates it around itself by <NUM>° so as to lay the front wall <NUM> on the support plate <NUM> and moving the component <NUM> from the seat <NUM> to the seat <NUM> (the component <NUM> was previously arranged in the seat <NUM> and the side wall <NUM> was previously resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S8 there also is a removal unit <NUM> (completely identical to the removal unit <NUM> present in the handling station S5), which, while the motor-driven arm <NUM> changes the position of the component <NUM> on the support plate <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S7).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the handling station S8 to the winding station S9, in which the carriage <NUM> stops and in which a winding unit <NUM> (completely identical to the winding unit <NUM> present in the winding station S3) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station S9 to the welding station S10 (arranged downstream of the winding station S9), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S9, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> present in the welding station S4). Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S10 to the handling station S11 (arranged downstream of the welding station S10), in which the carriage <NUM> stops and in which the component <NUM> is turned upside-down (namely, rotated around itself by <NUM>°) in order to be placed in the seat <NUM> of the carriage <NUM> by laying the rear wall <NUM> on the support plate <NUM> (namely, with the front wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the handling station S11 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> leaving the walls <NUM> and <NUM> completely free; when the carriage <NUM> is standing still in the handling station S11, the motor-driven arm <NUM> grabs the component <NUM> standing in the seat <NUM> of the carriage <NUM> and rotates it around itself by <NUM>° so as to lay the rear wall <NUM> on the support plate <NUM> (the front wall <NUM>, which is opposite the rear wall <NUM>, was previously resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S11 there also is a removal unit <NUM> (completely identical to the removal unit <NUM> present in the handling station S5), which, while the motor-driven arm <NUM> changes the position of the component <NUM> on the support plate <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S10).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the handling station <NUM> to the winding station S12, in which the carriage <NUM> stops and in which a winding unit <NUM> (completely identical to the winding unit <NUM> present in the winding station S3) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station S12 to the welding station S13 (arranged downstream of the winding station S12), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S12, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> present in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S13 to the handling station S14 (arranged downstream of the welding station S13), in which the carriage <NUM> stops and in which the component <NUM> is rotated by <NUM>° in order to be placed in the seat <NUM> of the carriage <NUM> by laying the upper wall <NUM> on the support plate <NUM> (namely, with the lower wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the handling station S14 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> leaving the upper wall <NUM> completely free; when the carriage <NUM> is standing still in the handling station S <NUM>, the motor-driven arm <NUM> grabs the component <NUM> standing in the seat <NUM> of the carriage <NUM> and rotates it around itself by <NUM>° so as to lay the upper wall <NUM> on the support plate <NUM> and moving the component <NUM> from the seat <NUM> to the seat <NUM> (the component <NUM> was previously located in the seat <NUM> and the rear wall <NUM> was previously resting on the support plate <NUM>). According to a preferred embodiment, in the handling station S14 there also is a removal unit <NUM> (completely identical to the removal unit <NUM> present in the handling station S5), which, while the motor-driven arm <NUM> changes the position of the component <NUM> on the support plate <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S13).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the handling station S14 to the winding station S15, in which the carriage <NUM> stops and in which a winding unit <NUM> (completely identical to the winding unit <NUM> present in the winding station S3) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station <NUM> to the welding station S16 (arranged downstream of the winding station S15), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S15, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> present in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S16 to the handling station S17 (arranged downstream of the welding station S16), in which the carriage <NUM> stops and in which the component <NUM> is turned upside-down (namely, rotated on itself by <NUM>°) in order to be placed in the seat <NUM> of the carriage <NUM> by laying the lower wall <NUM> on the support plate <NUM> (namely, with the upper wall <NUM> arranged horizontally and in the highest point). According to <FIG>, in the handling station S17 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> leaving the upper wall <NUM> and the lower wall <NUM> completely free; when the carriage <NUM> is standing still in the handling station S <NUM>, the motor-driven arm <NUM> grabs the component <NUM> standing in the seat <NUM> of the carriage <NUM> and rotates it around itself by <NUM>° so as to lay the lower wall <NUM> on the support plate <NUM> (the upper wall <NUM>, which is opposite the lower wall <NUM>, was previously resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S17 there also is a removal unit <NUM> (completely identical to the removal unit <NUM> present in the handling station S5), which, while the motor-driven arm <NUM> changes the position of the component <NUM> on the support plate <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S16).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the handling station S17 to the winding station S18, in which the carriage <NUM> stops and in which a winding unit <NUM> (completely identical to the winding unit <NUM> present in the winding station S3) winds an externally insulated conductor wire <NUM> around the component <NUM> carried by the carriage <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the winding station S15 to the welding station S19 (arranged downstream of the winding station S18), in which the carriage <NUM> stops and in which the two opposite ends of the coils <NUM>, which was wound in the previous winding station S <NUM>, are welded (for example, through ultrasounds, through heat sealing or through laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> present in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> in its own seat <NUM>) along the winding path P and from the welding station S <NUM> to the output station S2 (arranged downstream of the welding station S <NUM>), in which the carriage <NUM> stops and in which the component <NUM> is retrieved from the seat <NUM> in order to be directed towards an output of the machine <NUM>. According to <FIG>, in the output station S2 there is a motor-driven arm <NUM> provided with a holding head <NUM>, which is designed to grab the component <NUM> in order to retrieve the component <NUM>.

According to a preferred embodiment, in the output station S2 there also is a removal unit <NUM> (completely identical to the removal unit <NUM> present in the handling station S5), which, while the motor-driven arm <NUM> retrieves the component <NUM>, removes (eliminates) excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S19). One single winding unit <NUM> will be described hereinafter, since all six winding units <NUM> are substantially identical to one another and operate all in the same way.

According to <FIG>, each carriage <NUM> comprises, for each seat <NUM>, <NUM> or <NUM>, two clamps <NUM> and <NUM> (better shown in <FIG>), which are mounted on the support plate <NUM> under the seat <NUM>, <NUM> or <NUM> and are arranged side by side. Each clamp <NUM> or <NUM> is designed to hold and lock a corresponding end of the wire <NUM> to be wound around the respective component <NUM> and is provided with one single movable jaw, which moves back and forth along a horizontal holding direction D1, which is perpendicular to the winding path P (shown in <FIG>). In other words, each clamp <NUM> or <NUM> opens and closes by means of a movement developing along the holding direction D1 and, therefore, is perpendicular to the winding path P so that, by closing, the clamps <NUM> and <NUM> cause the wire <NUM> to come into contact with the corresponding electrical contacts <NUM>. In particular, in use, the clamp <NUM> is used to grab an initial end of the wire <NUM> at the beginning of the winding of the wire <NUM> around the component <NUM> (i.e. before winding the wire <NUM> around the component <NUM>, its initial end is grabbed by the clamp <NUM>); on the other hand, in use, the clamp <NUM> is used to grab a final end of the wire <NUM> at the end of the winding of the wire <NUM> around the component <NUM> (i.e. after having completed the winding of the wire <NUM> around the component <NUM>, its final end is grabbed by the clamp <NUM>).

The movable jaw of each clamp <NUM> or <NUM> is moved along the holding direction D1 by means of a control rod <NUM> (shown in <FIG>), which is arranged through the support plate <NUM> and comes out from the back of the support plate <NUM> in order to be pushed by and actuator device <NUM> (shown in <FIG>) located in a fixed position (namely, mounted on the frame of the machine <NUM>) in the area of each winding unit <NUM> (namely, in the area of each winding station S3, S6, S9, S12, S15, S18). Preferably, each clamp <NUM> or <NUM> normally is closed, namely, in the absence of an intervention of the actuator device <NUM>, it naturally remains closed; this result is obtained thanks to the presence of a spring, which tends to push the movable jaw of each clamp <NUM> or <NUM> towards the closed position and is compressed by the action of the actuator device <NUM> (namely, the actuator device <NUM> must overcome the elastic force generated by the spring in order to move the movable jaw of each clamp <NUM> or <NUM> towards the open position).

In each winding unit <NUM> there are two clamps <NUM> and <NUM>, which are mounted (on the frame of the machine <NUM> and, hence, on the outside of the main conveyor <NUM>, so as not to move together with the carriages <NUM>) under the support plates <NUM> of the carriages <NUM> and are arranged next to one another; in particular, the pair of clamps <NUM> and <NUM> is vertically aligned with a corresponding pair of clamps <NUM> and <NUM> carried by a carriage <NUM>, which stops in the area of the winding unit <NUM>.

Each clamp <NUM> or <NUM> is designed to hold and lock a corresponding end of the wire <NUM> to be wound around the respective component <NUM> and is provided with one single movable jaw, which moves back and forth along a horizontal holding direction D2, which is parallel to the winding path P (namely, perpendicular to the holding direction D1 and shown in <FIG>). In other words, each clamp <NUM> or <NUM> opens and closes by means of a movement developing along the holding direction D2 and, therefore, is parallel to the winding path P. According to a preferred embodiment shown in the accompanying figures, the clamps <NUM> and <NUM> share a common jaw without movement arranged between the clamps <NUM> and <NUM>.

In particular, in use, the clamp <NUM> is used to grab the initial end of the wire <NUM> at the beginning of the winding of the wire <NUM> around the component <NUM> and (immediately) before the initial end of the wire <NUM> is grabbed by the clamp <NUM> above; on the other hand, in use, the clamp <NUM> is used to grab the final end of the wire <NUM> at the end of the winding of the wire <NUM> around the component <NUM> and (immediately) after the final end of the wire <NUM> is grabbed by the clamp <NUM> above.

Preferably, each clamp <NUM> or <NUM> normally is closed, namely, in the absence of an intervention of an actuator device, it naturally remains closed; this result is obtained thanks to the presence of a spring, which tends to push the movable jaw of each clamp <NUM> or <NUM> towards the closed position and is compressed by the action of the actuator device (namely, the actuator device must overcome the elastic force generated by the spring in order to move the movable jaw of each clamp <NUM> or <NUM> towards the open position). Each winding unit <NUM> comprises a blade <NUM>, which is mounted (on the frame of the machine <NUM> and, hence, on the outside of the main conveyor <NUM> so as not to move together with the carriages <NUM>) under the support plates <NUM> of the carriages <NUM> in order to be, in use, between a respective clamp <NUM> carried by a carriage <NUM> and a respective clamp <NUM>.

Each blade <NUM> is, in use, movable along a cutting direction coinciding with the holding direction D2 (shown in <FIG>), namely each blade <NUM> moves back and forth by means of a movement parallel to the winding path P. Thanks to its position, each movable blade <NUM> can cut a final end of a wire <NUM>, which is locked higher by a respective clamp <NUM> carried by a carriage <NUM>, and is locked lower by a respective clamp <NUM>.

Each winding unit <NUM> comprises a movable finger <NUM>, which is used to bring the wire <NUM> close to the component <NUM> in order to wind the wire <NUM> around the component <NUM> and, hence, move the wire <NUM> away from the component <NUM>. Each movable finger <NUM> has a tubular shape having a central hole going through the movable finger <NUM> from side to side and accommodating the wire <NUM>; namely, the wire <NUM> is inserted into a rear opening of the movable finger <NUM> and comes out from a front opening of the movable finger <NUM>. For each movable finger <NUM>, the wire <NUM> is progressively unwound from a reel contained in a suitable container, goes through a stretching device provided with at least one movable dandy roller operated by a spring and, then, reaches the movable finger <NUM>; each stretching device is configured to apply an always constant stretch to the wire <NUM>.

The winding unit <NUM> comprises a common support body <NUM> (shown in <FIG>), on which the movable finger <NUM> is mounted in order to move the movable finger <NUM>; in particular, the movable finger <NUM> is mounted on the support body <NUM> in a rigid manner, namely the movable finger <NUM> always moves with the support body <NUM> in an integral manner and never makes any kind of movement relative to the support body <NUM>. The support body <NUM> is moved by one single actuator device <NUM> (schematically shown in <FIG>) provided with (at least) an independent electric motor of its own. In use, each movable finger <NUM> is placed with a horizontal orientation when the wire <NUM> has to be vertically moved in order to go up getting close to the component <NUM> or in order to go down moving away from the component <NUM>; furthermore, in use, each movable finger <NUM> is placed with a vertical orientation when the wire <NUM> has to be horizontally moved in order be wound around the component <NUM>.

Each winding unit <NUM> comprises a containing body <NUM> (better shown in <FIG>), which, in use, is laid against the pin <NUM> so as to extend the pin <NUM> when the wire <NUM> has to be bent around the pin <NUM> in order to prevent the wire <NUM> from accidentally slipping away from the pin <NUM>; namely, shortly before the wire <NUM> is bent by <NUM>° around the pin <NUM>, the containing body <NUM> is laid against the pin <NUM> in order to extend the pin <NUM>, thus preventing the wire <NUM> from accidentally slipping away from the pin <NUM>. To this regard, it should be pointed out that the pin <NUM> cannot be too large (due to space problems that are not related to the machine <NUM>) and, at the same time, the movable finger <NUM> cannot get too close to the component <NUM> when moving in order to prevent small positioning errors (together with constructive tolerances of the component <NUM>) from causing accidental hits of the movable finger <NUM> against the component <NUM>.

According to a preferred embodiment shown in the accompanying figures, each winding unit <NUM> comprises a further movable finger <NUM> (better shown in <FIG>), which is arranged under the two clamps <NUM> and <NUM> and between the two clamps <NUM> and <NUM> (namely, under the common jaw without movement arranged between the clamps <NUM> and <NUM>) and is vertically moved in order to remove the initial end of the wire <NUM>, which can remain inside the clamp <NUM> even when the clamp <NUM> is opened (the initial end of the wire <NUM> is very light and, hence, it often does not manage to naturally remove itself from the clamp <NUM> due to gravity); in this way, namely, thanks to the removing action exerted by the movable finger <NUM>, the initial end of the wire <NUM> is prevented from remaining inside the clamp <NUM> in an undesired manner, thus breaking due to tearing when the carriage <NUM> moves at the end of the winding. In particular, the clamp <NUM> is opened after the initial end of the wire <NUM> has been engaged by the clamp <NUM> in order to begin a new winding and, at this point, the movable finger <NUM> makes a vertical downward work stroke to remove the initial end of the wire <NUM> from the clamp <NUM>.

The winding of a wire <NUM> around a component <NUM> in one single winding unit <NUM> will be described below; obviously, the operations carried out in one single winding unit <NUM> are simultaneously carried out - in the exact same manner - also in the other winding units <NUM>.

At first, the winding unit <NUM> is empty (namely, lacks the component <NUM> carried by a carriage <NUM>), an initial end of the wire <NUM> is locked in the clamp <NUM> and the movable finger <NUM> (arranged horizontally) is under the clamp <NUM>. The initial end of the wire <NUM> locked in the clamp <NUM> is the initial end with reference to the new winding that has to be performed around the next component <NUM> that is about to reach the winding unit <NUM>, while, on the other hand, it was the final end of the wire <NUM> with reference to the previous winding that was completed around the previous component <NUM> that was previously located in the winding unit <NUM>. When the machine <NUM> is started after a replacement of the reels from which the wire <NUM> is unwound, an operator manually places the initial end of the wire <NUM> in the clamp <NUM>.

Subsequently, the carriage <NUM> moves the component <NUM> to the winding unit <NUM>, the clamps <NUM> and <NUM> open, the movable finger <NUM> (still arranged horizontally) vertically moves from the bottom to the top in order to cause the initial end of the wire <NUM> to go, at first, through the clamp <NUM> and, subsequently, through the clamp <NUM> and, finally, the clamps <NUM> and <NUM> close in order to lock (in two different points) the initial end of the wire <NUM>; preferably, the sole clamp <NUM> closes at first, while the clamp <NUM> is still open and, subsequently, the clamp <NUM> closes as well. It should be pointed out that the clamp <NUM> opens and closes by means of a movement along the holding direction D1, which is perpendicular to the winding path P, and, hence, in the closing movement, the clamp <NUM> moves the wire <NUM> perpendicular to the winding path P by pulling the wire <NUM> against the component <NUM> so that the wire <NUM> rests on a corresponding electrical contact <NUM>.

Subsequently, the movable finger <NUM> rotates by <NUM>° so as to move from a horizontal orientation to a vertical orientation and starts to rotate around the component <NUM> in order to wind the wire <NUM> around the component <NUM>. Before starting to wind the wire <NUM> around the component <NUM>, the wire <NUM> vertically going up towards the component <NUM> is bent by the movable finger <NUM> around the pin <NUM>, which horizontally projects from the component <NUM>, in order to cause the wire <NUM> to make a <NUM>° turn, which deflects the wire <NUM> towards a horizontal orientation. In particular, the <NUM>° rotation of the movable finger <NUM> moving from a horizontal orientation to a vertical orientation takes place simultaneously with the bending of the wire <NUM> around the pin <NUM>. As mentioned above, in this step, the containing body <NUM> is laid against the pin <NUM> in order to extend the pin <NUM> when the wire <NUM> has to be bent around the pin <NUM>, thus preventing the wire <NUM> from accidentally slipping away from the pin <NUM>.

Subsequently, the movable finger <NUM> makes a series of laps around the component <NUM> in order to obtain, with the wire <NUM>, a series of (vertically staggered) turns around the component <NUM>.

Approximately when the wire <NUM> starts to be wound around the component <NUM>, the clamp <NUM> opens and the movable finger <NUM> makes a vertical downward work stroke to remove the initial end of the wire <NUM> from the clamp <NUM>.

When the winding of the wire <NUM> around the component <NUM> is almost complete (namely, before ending the last turn of the winding), the containing body <NUM> is moved away from the component <NUM> and (preferably) the clamp <NUM> is opened to free the initial end of the wire <NUM> (while the clamp <NUM> remains closed).

After having ended winding the wire <NUM> around the component <NUM>, the movable finger <NUM> bends the horizontally arranged wire <NUM> around the pin <NUM> in order to cause the wire <NUM> to make a <NUM>° turn, which deflects the wire <NUM> towards a vertical orientation. Simultaneously with the bending of the wire <NUM> around the pin <NUM>, the movable finger <NUM> rotates by <NUM>° in order to move from a vertical orientation to a horizontal orientation. As mentioned above, in this step, the containing body <NUM> is laid against the pin <NUM> in order to extend the pin <NUM> when the wire <NUM> has to be bent around the pin <NUM>, thus preventing the wire <NUM> from accidentally slipping away from the pin <NUM>.

When the end of the winding of the wire <NUM> around the component <NUM> is close (namely, before completing the last turn of the winding), the pin <NUM> is opened. The movable finger <NUM>, by vertically moving the wire <NUM> from the top to the bottom after having bent the wire <NUM> around the pin <NUM>, causes the final end of the wire <NUM> to go through the open clamp <NUM>, which closes immediately after, hence locking the final end of the wire <NUM>; subsequently, the movable finger <NUM>, by vertically moving the wire <NUM> from the top to the bottom after having bent the wire <NUM> around the pin <NUM>, causes the final end of the wire <NUM> to also go through the open clamp <NUM>, which closes immediately after, hence locking the final end of the wire <NUM>. It should be pointed out that the clamp <NUM> opens and closes by means of a movement along the holding direction D1, which is perpendicular to the winding path P, and, hence, in the closing movement, the clamp <NUM> moves the wire <NUM> perpendicular to the winding path P by pulling the wire <NUM> against the component <NUM> so that the wire <NUM> rests on a corresponding electrical contact <NUM>.

Subsequently, the containing body <NUM> moves away from the component <NUM> and the winding manufacturing process ends with the movement of the movable blade <NUM>, which, by moving parallel to the winding path P, cuts the final end of the wire <NUM> after the final end of the wire <NUM> has been locked both by the clamp <NUM> and by the clamp <NUM> (namely, the movable blade <NUM> cuts the final end of the wire <NUM> between the portion locked higher by the clamp <NUM> and the portion locked lower by the clamp <NUM>).

According to a possible embodiment, the winding of the wire <NUM> around the component <NUM> is carried out from the bottom to the top; hence, before starting the winding of the wire <NUM>, the wire <NUM> vertically going up towards the component <NUM> is bent around the pin <NUM> (arranged lower) in order to cause the wire <NUM> to make a <NUM>° turn, which deflects the wire <NUM> towards a horizontal orientation; furthermore, after having ended the winding of the wire <NUM>, the horizontally arranged wire <NUM> is bent around the pin <NUM> (arranged higher) in order to cause the wire <NUM> to make a <NUM>° bend, which deflects the wire <NUM> towards a vertical orientation. According to a different embodiment, the winding of the wire <NUM> around the component <NUM> is carried out from the top to the bottom; hence, before starting the winding of the wire <NUM>, the wire <NUM> vertically going up towards the component <NUM> is bent around the pin <NUM> (arranged higher) in order to cause the wire <NUM> to make a <NUM>° turn, which deflects the wire <NUM> towards a horizontal orientation; furthermore, after having ended the winding of the wire <NUM>, the horizontally arranged wire <NUM> is bent around the pin <NUM> (arranged lower) in order to cause the wire <NUM> to make a <NUM>° bend, which deflects the wire <NUM> towards a vertical orientation. In this embodiment, the winding of the wire <NUM> around the component <NUM> takes place above a vertical segment of the wire <NUM> reaching the pin <NUM> (arranged higher) and, hence, helps lock the initial end of the wire <NUM> against the component <NUM>, ensuring a greater stability of the winding.

According to <FIG>, the welding station S4 comprises a corresponding welding unit <NUM>, which is arranged in a fixed position (namely, does not move together with the main conveyor <NUM>) and is provided with a movable welding head <NUM> to get close to the component <NUM> carried by a carriage <NUM> standing still in the welding station S4 so as to weld the two ends of the wire <NUM> to the corresponding electrical contacts <NUM> and, subsequently, move away from the component <NUM> carried by the carriage <NUM> once the welding has ended. The movement of the welding head <NUM> always is linear and can be oriented vertically (which is the case in the welding stations S4, S7, S10 and S13) or can be oriented horizontally (which is the case in the welding stations S16 and S19) depending on the orientation assumed by the component <NUM>. The welding head <NUM> is provided with two welding elements next to one another to simultaneously weld both ends of the wire <NUM> to the corresponding electrical contacts <NUM>. Preferably, the welding head <NUM> is also configured to cut the two ends of the wire <NUM> downstream of the welds to the two electrical contacts <NUM>, so as to separate the excess part of the two opposite ends of the coil <NUM>-<NUM>; namely, the welding head <NUM> is also provided with blades, which cut the wire <NUM> downstream of the welds to the two electrical contacts <NUM>.

As mentioned above, in all six welding stations S4, S7, S10, S13, S16 and S19, the corresponding six welding units <NUM> are substantially identical to one another and the only significant change lies in the vertical orientation of the welding heads <NUM> in the welding stations S4, S7, S10 and S13 and in the horizontal orientation of the welding heads <NUM> in the welding stations S16 and S19 to adjust to the different orientations of the components <NUM>.

According to <FIG>, the handling station S5 comprises a corresponding removal unit <NUM> provided with a blower device <NUM>, which is connected to a common compressed air distributor and is configured to generate a compressed air blow, which is directed from the top to the bottom and hits a corresponding component <NUM> carried by a carriage <NUM> standing still in the removal station S5. The compressed air blow hits from the top to the bottom a corresponding component <NUM> carried by a carriage <NUM> standing still in the removal station S5 and, then, pushes downwards the excess parts of the two opposite ends of the coil <NUM>-<NUM> (cut in the previous welding station S4); preferably, the excess parts of the two opposite ends of the coil <NUM>-<NUM> pushed downwards by a compressed air blow are collected in a container <NUM> located under the carriage <NUM>. According to a preferred embodiment, the removal unit <NUM> also comprises a clamp <NUM>, which is arranged in a fixed position (namely, on the outside of the main conveyor <NUM>) under the support plate <NUM> of a carriage <NUM> standing still and grabs the excess parts of the two opposite ends of the coil <NUM>-<NUM> while waiting for the excess parts to be directed into the container <NUM> by the air blows.

As mentioned above, in all five handling stations S5, S8, S11, S14, S17 and S19 and in the output station S2, the corresponding six removal units <NUM> are substantially identical to one another.

In the embodiment described above, in the five handling stations S5, S8, S11, S14, S17 and S19, each component <NUM> is rotated by <NUM>° or <NUM>° around a horizontal rotation axis; according to other embodiments, in one or more handling stations S5, S8, S11, S14, S17 and S19, each component <NUM> is rotated around several different rotation axes: for example, each component <NUM> is rotated at first by <NUM>° or <NUM>° (or even by a different angle, such as <NUM>°, <NUM>° or others) around a horizontal rotation axis and then is rotated by <NUM>° or <NUM>° (or even by a different angle, such as <NUM>°, <NUM>° or others) around a vertical rotation axis.

In the non-limiting embodiment described above, the component <NUM> is part of a disposable cartridge of an electronic cigarette, but the method to manufacture coils <NUM>-<NUM> described above can also be applied to the production of components for articles of any type (namely, of any product class). For example, the method to manufacture coils <NUM>-<NUM> described above can be applied to the production of components for a machine, a plant, a construction, for example, but not exclusively, of the tobacco, pharmaceutical, food-related or entertainment industry; more in general, the method to manufacture coils <NUM>-<NUM> described above can be applied to the production of components for applications of any type.

The embodiments described herein can be combined with one another, without for this reason going beyond the scope of protection of the invention as claimed.

The method to manufacture coils <NUM>-<NUM> described above have numerous advantages. First of all, the method to manufacture coils <NUM>-<NUM> described above allows for an operation at a high operating speed (measured as number of components produced per time unit). Furthermore, the method to manufacture coils <NUM>-<NUM> described above maintains a high productive quality (generally measured as percentage of faulty pieces).

Claim 1:
A method to manufacture at least two different coils (<NUM>-<NUM>) around a component (<NUM>) of an article; the method comprises the steps of:
moving, by means of a main conveyor (<NUM>) and along a winding path (P), a carriage (<NUM>) carrying at least one seat (<NUM>, <NUM>, <NUM>) designed to house the component (<NUM>);
placing, in an input station (S1) arranged along the winding path (P), the component (<NUM>) in the seat (<NUM>, <NUM>, <NUM>) of the carriage (<NUM>); characterized by
winding, in a first winding station (S3) arranged along the winding path (P) downstream of the input station (S1), a first externally insulated conductor wire (<NUM>) around the component (<NUM>) in order to obtain a series of turns making up a first coil (<NUM>-<NUM>); and
winding, in a second winding station (S6) arranged along the winding path (P) downstream of the first winding station (S3), a second externally insulated conductor wire (<NUM>) around the component (<NUM>) in order to obtain a series of turns making up a second coil (<NUM>-<NUM>);
changing, in a first handling station (S5) arranged along the winding path (P) between the first winding station (S3) and the second winding station (S6), the orientation of the component (<NUM>) relative to the carriage (<NUM>).